description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
The invention concerns a method and a device for the treatment of a tension-sensitive textile web. The invention serves to subject continuously guided textile webs to washing, impregnation or other treatments with a liquid treatment medium.
The invention concerns a method and a device for the treatment of a tension-sensitive textile web. The invention serves to subject continuously guided textile webs to washing, impregnation or other treatments with a liquid treatment medium.
BACKGROUND OF THE INVENTION
It is known to apply the treatment medium via nozzles onto the textile web, the application occurring on a straight section of the web or on a section of the web which is curved around a roller. Internation publication WO 91/04367 describes a treatment method where the textile web is guided in an extended condition through a narrow shaft, and where if necessary different treatment mediums, such as water, hot vapour or hot air are applied to the textile web under pressure. For the treatment of knitted goods, such as tricot, this method is unsuitable because of its relatively long unsupported lengths. A related and comparable device is made known in German document DE-A-25 21 407, where the treatment medium is sprayed onto the web and is then immediately removed from the same side of the web by suction. This procedure can be carried out both on straight and curved sections of the web. Extended action of the treatment medium on the textile web is here not possible, the case with vaporific treatment mediums. German document DE-A-19 17 759 describes the treatment of a tension-sensitive textile web, with the textile web being guided along a continuously constrained web path around rollers through which a treatment liquid flows. Forced penetration of the liquid through the textile web does occur, although its effect will not be as intensive as is possible when using nozzles.
SUMMARY OF THE INVENTION
It is therefore a purpose of the invention to create a method and a device of the type mentioned above in order to achieve intensive treatment while exploiting a jet effect, for knitted goods which are elastic in the longitudinal direction, and for textile webs which are sensitive to tension. This purpose is fulfilled by the method and apparatus described below.
The extension of the narrow shaft around the wrap-around area of the rollers together with the arrangement of nozzles in the curved area will on the one hand enable exploitation of the entire travel distance of the textile web. In the curved area, the textile web attains a tensioned surface and will thus be particularly absorbent with regard to treatment medium. The rollers can be placed relatively close to each other so than no potentially damaging freely-suspended lengths are required. An intense flow will develop over the entire length of the shaft, taking effect on the textile web for the entire time it passes through the shaft.
Preferably, the textile web within the shaft is subjected to curving at least once on each of its sides while being acted upon by the treatment medium. With that, equally intense treatment on both sides will be ensured. This is particularly significant in the case of guided wide, tubular knitted-fabric, for example.
In certain cases it is also conceivable to arrange the curved shaft around a single roller only, curving the shaft through 180° and employing auxiliary rollers, for example.
During treatment, the textile web can also be guided with a continuously constrained web path, so that the individual rollers are almost in contact with each other. In this case, the shaft then assumes a continuously and alternatingly curved shape.
For certain treatment procedures it is also advantageous if the textile web is first of all guided around an upper roller where the treatment medium is applied under pressure, and if the textile web is then guided around a lower roller where it is immersed in a bath containing liquid treatment medium. The curved shaft can in this case be completely filled with liquid at the lower roller, which nevertheless does not preclude that liquid from being directed under pressure onto the textile web in this area. The lower shaft can, however, also serve merely as a collector reservoir for treatment medium from the upper shaft.
Hot vapour, saturated steam or water can be applied to the textile web under pressure either in combination or separately. It is at the same time also conceivable to connect individual nozzles to different treatment medium sources, or to alternate these connections by means of corresponding control valves.
Particulary good results can be achieved on the surface of the textile web if, in relation to the course of the shaft, liquid and vaporific treatment mediums are applied alternately. The surface of the textile web will be disrupted through pressurised application of hot vapour, and the application of liquid, in particular fresh water, will raise the wash-effect.
The two consecutively arranged rollers preferably form at least two opposing curved sections. In certain cases it is also conceivable that the curved shaft with nozzles may be provided only at one roller, while the other roller possesses either no curved shaft at all, or a shaft without nozzles, the shaft only being rinsed through with a liquid, for example.
A straight shaft section can be arranged between both curved shaft sections or between both rollers. For example, a machine for washing printed textile webs can be constructed with particular advantage if two rollers are arranged one above the other, with a shaft extending around the upper surface of the upper roller and a shaft extending around the bottom surface of the lower roller, and if the surfaces of the rollers facing each other which are not associated with a shaft are enclosed by a common housing. The liquid or distillate from the upper shaft will in this case run freely into the lower shaft, the lower shaft in principle taking the form of a bath.
It is also not absolutely necessary that the rollers have a closed and regular surface. At least one roller can be designed as a perforated drum, for example, its inside being able to be connected to a suction-extraction means. Either axially or circumferentially, the rollers or drums could also possess a corrugated shape. The distance between the walls of the shaft lies within the range of 3 to 30 mm, preferably between 5 and 10 mm.
Extraction of liquid or gaseous treatment medium from the shaft is accomplished by appropriate drainage piping in the walls of the shaft.
In certain cases, it can be appropriate to suitably support the tension-sensitive textile web not only in the curved area of the shaft, but also in a straight section of the shaft. For example, a continuous perforated band could be arranged in a straight section of the shaft, the perforated band being placed under a vacuum. The textile web will in this way be forced against the perforated band and thus protected from excessive tensile loading. The perforated band could also be wrapped around the rollers, so that the textile web in the curved section of the shaft would make contact not directly with the surface of the rollers, but rather on the perforated band.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are shown in the drawings and will be more closely described below.
FIG. 1 is a longitudinal section through a shaft possessing two rollers and with a straight intermediate section,
FIG. 2 is a longitudinal section through a shaft with three rollers for web guidance with a continuously constrained web path,
FIG. 3 is a cross section through a shaft with a corrugated roller and hollow drive-shaft,
FIG. 4 is a longitudinal section through an embodiment with an S-shaped shaft arrangement,
FIG. 5 is a cross section through a washing compartment with two rollers, one placed above the other,
FIG. 6 is a somewhat truncated view of the machine according to FIG. 5, seen in the direction of feed, and
FIG. 7 shows a further embodiment possessing a perforated band for supporting the textile web.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Highly diagrammatic, FIG. 1 shows a textile web 1, for example knitted goods which are sensitive to tension, the textile web being guided through a relatively restricted shaft 5 over preferably two driven rollers 3 and 4. The textile web is transported further over a deflection roller 10 in the direction of the arrow a. At the same time, the rollers rotate in the direction b, with the roller 10 also able to be a driven roller. In the wrap-around area of the rollers, the shaft 5 possesses two curved sections 6, and 6', with the surface of the rollers directly forming a section of the shaft at these locations. Nozzles 7 are arranged in the curved sections, the nozzles being connected to supply piping 9 or 9'. These nozzles can be cone-type nozzles or slotted nozzles extending over the entire width of the textile web. A straight section 8 is arranged between the rollers 2 and 3, on which nozzles 7 are likewise arranged on both sides of the textile web. Evidently, the textile web in this arrangement is subjected to curvature at least once on each side and at the same time acted upon by the treatment medium. The intensive mechanical loading on the textile web, combined with the treatment medium injected under pressure into the shaft, leads to deep penetration of the textile web. Vibration of the textile web can result in the free straight sections, which will further improve the effect. The rollers can possess a diameter of, for example, 40-80 cm. A mixture of vapour, air and water can be applied through the nozzles, with a treatment liquor other than water also being conceivable. The nozzles can either all be connected to the same source of treatment medium, or individual nozzles or groups of nozzles can be connected to different sources of treatment medium.
FIG. 2 shows an alternative embodiment of a treatment device with which the shaft is formed by three rollers 2, 3 and 4, said rollers guiding the web along a continuously constrained web path. Here, too, at least one nozzle is arranged in the area of each curvature 6, 6' and 6". A pair of nozzles is also provided in the straight inlet section 15 of the shaft.
FIG. 3 shows a cross section through a shaft in the area of a roller 2, the roller being provided with circumferential corrugations 11. The roller is designed as a hollow roller and is provided with openings 12. A suction pipe 14 leads into the inside of the roller so that vapour and/or liquid can be removed by suction. The nozzle 7 is designed as a continuous slotted nozzle with individual connections. The wall of the shaft 13 completely encloses the roller, around its entire outer circumference, with a definite shaft width naturally being provided only in the region of the textile web 1. On the rear side, the shaft wall 13 encloses the roller to the extent that contact is only just avoided. As suggested in FIGS. 1 and 2, the shaft wall 13 could enclose the rollers only in the wrap-around areas, with suitable seals naturally being required to be incorporated with regard to the freely rotating roller sections.
With the embodiment according to FIG. 4, the shaft 5 has an approximately S-shaped cross-sectional design. The deflection roller 10 guides the textile web 1 from the horizontal directly into the curved area 6 of the first roller 2. Extraction over the deflection roller 10' is done at almost the same level in the direction of the arrow a. A vapour-air-water mixture is applied to the textile web from the collector tubes 16 integrated into the wall of the shaft. The driven rollers or drums 2 and 3 can possess a structured surface so that the textile web only makes partial contact. As a result, sections will be formed which can oscillate freely under the influence of the treatment medium.
In the case of the washing machine according to FIGS. 5 and 6, the arrangement of rollers is in principle the same as in the embodiment according to FIG. 4. An upper drum 18 and a lower drum 19 is in each case mounted in bearings to rotate in a machine frame 17. The rotational axes of both drums lie in the same vertical plane. Drive motors 20, 20' are arranged outside on the machine frame, said motors not only driving both the drums by means of toothed belts or v-belts, but also the individual deflection rollers 27.
An upper shaft 21 is arranged at the upper drum 18 which extends approximately 180° over the upper surface of said drum. The distance between the drum and the wall of the shaft is extremely small, for example 5 mm. A plurality of upper nozzle-tubes 25 extend over the entire width of the shaft, said tubes being equipped with slotted nozzles or with bores.
The lower drum 19 is equipped with individual corrugations 28 at regular intervals, so that the textile web makes only linear contact. The lower shaft 22 extends around the bottom surface of the drum 19, likewise through an angle approaching 180°. In comparison to the upper shaft, however, the lower shaft has a considerably greater distance between the drum and the wall of the shaft of 10-40 mm. Nozzle tubes 26 extending over the entire width of the shaft are also arranged at the lower shaft.
The facing drum surfaces which are not associated with a shaft are connected by a common housing 23. A plurality of window-flaps 24 are arranged in the sides of the said housing, those flaps facilitating the introduction of the textile web and permitting monitoring of the washing process during operation.
As opposed to the embodiment according to FIG. 4, the textile web 1 is guided over deflection rollers 27 first of all to the upper drum 18, although wrapping around the rollers approximately is likewise in an S-shape. In the upper shaft 21, the textile web is intensively acted upon with vapour, if necessary also alternating with fresh water.
The transition to the lower drum 19 follows with a free span within the housing 23. The lower shaft 22 is completely filled with liquor, although this liquor is continuously replaced. Liquor is pumped under pressure against the surface of the textile web through the nozzle tubes 26. The nozzle tubes 26 could, however, be switched off and the supply or recirculation of liquor could be carried out using another means.
The textile web is extracted from the washing compartment around a further deflection roller in the direction of the arrow a. Preferably, a plurality of such washing compartments are connected in series.
With the embodiment according to FIG. 7, the textile web 1 is guided through the shaft 35 on a perforated band 31. The continuous perforated band is tensioned between an upper roller 29 and a lower roller 30. Nozzles 34 are arranged in the wall of the shaft 33, said wall extending around the surface of the rollers. In the straight area of the shaft, a partial-vacuum chamber 32 is arranged on the inside of the perforated band, said chamber being open towards the perforated band. In the area of this partial-vacuum chamber, the textile web 1 is evidently pressed against the perforated band and thus stabilised in the straight area of the shaft. In addition, the partial-vacuum also causes the treatment medium which has been sprayed onto the side oriented away from the chamber 32 to be drawn by suction though the textile web. The suction effect could of course also be maintained in the area of both the rollers 29, 30 by designing these rollers as perforated rollers.
Inasmuch as the invention is subject to modifications and variations, the foregoing description and accompanying drawings should not be regarded as limiting the invention, which is defined by the following claims and various combinations thereof. | The textile web (1) is guided through a relatively narrow shaft the limits of which are formed at least partially by the surface of rollers (2, 3). Nozzles (7), from which a treatment medium can be applied onto the textile web, are arranged in the curved sections (6, 6') of the shaft. Straight sections (8) between the rollers can be kept very short. The device is especially suitable for the treatment of tension-sensitive textile webs. | 3 |
RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 60/774,442, filed Feb. 17, 2006, U.S. Provisional Patent Application Ser. No. 60/774,587, filed Feb. 17, 2006, and U.S. Provisional Patent Application Ser. No. 60/774,920, filed Feb. 17, 2006, the disclosures of each of which is incorporated herein by reference in its entirety.
[0002] This application is related to: Mark E. Van Dyke, U.S. patent application Ser. No. 11/205,800, titled: Ambient Stored Blood Plasma Expanders, filed Aug. 17, 2005; Mark E. Van Dyke, U.S. patent application titled: Nerve Regeneration Employing Keratin Biomaterials, filed Feb. 9, 2007 (serial number to be assigned); and Mark E. Van Dyke, U.S. patent application and PCT Application, titled: Clotting and Healing Compositions Containing Keratin Biomaterials, filed Feb. 16, 2007 (serial numbers to be assigned).
GOVERNMENT SUPPORT
[0003] This invention was made with Government support under contract number W81XWH-04-1-0105 from the United States Army. The U.S. Government has certain rights to this invention.
FIELD OF THE INVENTION
[0004] The present invention is generally related to keratin biomaterials and the use thereof in biomedical applications.
BACKGROUND OF THE INVENTION
[0005] The earliest documented use of keratin in medicine comes from a Chinese herbalist named Li Shi-Zhen (Ben Cao Gang Mu. Materia Medica, a dictionary of Chinese herbs, written by Li Shi Zhen (1518-1593)). Over a 38-year period, he wrote a collection of 800 books known as the Ben Cao Gang Mu . These books were published in 1596, three years after his death. Among the more than 11,000 prescriptions described in these volumes, is a substance known as Xue Yu Tan, also known as Crinis Carbonisatus, that is made up of ground ash from pyrolized human hair. The stated indications for Xue Yu Tan were accelerated wound healing and blood clotting.
[0006] In the early 1800s, when proteins were still being called albuminoids (albumin was a well known protein at that time), many different kinds of proteins were being discovered. Around 1849, the word “keratin” appears in the literature to describe the material that made up hard tissues such as animal horns and hooves (keratin comes from the Greek “kera” meaning horn). This new protein intrigued scientists because it did not behave like other proteins. For example, the normal methods used for dissolving proteins were ineffective with keratin. Although methods such as burning and grinding had been known for some time, many scientists and inventors were more interested in dissolving hair and horns in order to make better products.
[0007] The resolution to this insolubility problem came from a trade more than 700 years old—the tanning industry. In the years preceding World War I, lime was applied to the manufacture of keratin gels. In a United States patent issued in 1905, John Hoffmeier described a process for extracting keratins from animal horns using lime (German Pat No. 184,915, Dec. 18, 1905). He then used the extracted keratins to make gels that could be strengthened by adding formaldehyde (formaldehyde “crosslinking” is a popular method of strengthening such gels and is still used today to “fix” tissues containing structural proteins like keratin and collagen).
[0008] During the years from 1905 to 1935, many methods were developed to extract keratins using oxidative and reductive chemistries (Breinl F and Baudisch O, Z physiol Chem 1907; 52:158-69; Neuberg C, U.S. Pat. No. 926,999, Jul. 6, 1909; Lissizin T, Biochem Bull 1915; 4:18-23; Zdenko S, Z physiol Chem 1924; 136:160-72; Lissizin T, Z physiol Chem 1928; 173:309-11). By the late 1920s many techniques had been developed for breaking down the structures of hair, horns, and hooves, but scientists were confused by the behavior of some of these purified proteins. Scientists soon concluded that many different forms of keratin were present in these extracts, and that the hair fiber must be a complex structure, not simply a strand of protein. In 1934, a key research paper was published that described different types of keratins, distinguished primarily by having different molecular weights (Goddard D R and Michaelis L, J Biol Chem 1934; 106:605-14). This seminal paper demonstrated that there were many different keratin homologs, and that each played a different role in the structure and function of the hair follicle.
[0009] It was during the years of World War II and immediately after that one of the most comprehensive research projects on the structure and chemistry of hair fibers was undertaken. Driven by the commercialization of synthetic fibers such as Nylon and polyester, Australian scientists were charged with protecting the country's huge wool industry. Synthetic fibers were seen as a threat to Australia's dominance in wool production, and the Council for Scientific and Industrial Research (later the Commonwealth Scientific and Industrial Research Organisation or CSIRO) established the Division of Protein Chemistry in 1940. The goal of this fundamental research was to better understand the structure and chemistry of fibers so that the potential applications of wool and keratins could be expanded.
[0010] CSIRO scientists developed many methods for the extraction, separation, and identification of keratins. In 1965, CSIRO scientist W. Gordon Crewther and his colleagues published the definitive text on the chemistry of keratins (Crewther W G et al., The Chemistry of Keratins. Anfinsen C B Jr et al., editors. Advances in Protein Chemistry 1965. Academic Press. New York: 191-346). This chapter in Advances in Protein Chemistry contained references to more than 640 published studies on keratins. Once scientists knew how to extract keratins from hair fibers, purify and characterize them, the number of derivative materials that could be produced with keratins grew exponentially. In the decade beginning in 1970, methods to form extracted keratins into powders, films, gels, coatings, fibers, and foams were being developed and published by several research groups throughout the world (Anker C A, U.S. Pat. No. 3,642,498, Feb. 15, 1972; Kawano Y and Okamoto S, Kagaku To Seibutsu 1975; 13(5):291-223; Okamoto S, Nippon Shokuhin Kogyo Gakkaishi 1977; 24(1):40-50). All of these methods made use of the oxidative and reductive chemistries developed decades earlier.
[0011] In 1982, Japanese scientists published the first study describing the use of a keratin coating on vascular grafts as a way to eliminate blood clotting (Noishiki Y et al., Kobunshi Ronbunshu 1982; 39(4):221-7), as well as experiments on the biocompatibility of keratins (Ito H et al., Kobunshi Ronbunshu 1982; 39(4):249-56). Soon thereafter in 1985, two researchers from the UK published a review article speculating on the prospect of using keratin as the building block for new biomaterials development (Jarman T and Light J, World Biotech Rep 1985; 1:505-12). In 1992, the development and testing of a host of keratin-based biomaterials was the subject of a doctoral thesis for French graduate student Isabelle Valherie (Valherie I and Gagnieu C. Chemical modifications of keratins: Preparation of biomaterials and study of their physical, physiochemical and biological properties. Doctoral thesis. Inst Natl Sci Appl Lyon, France 1992). Soon thereafter, Japanese scientists published a commentary in 1993 on the prominent position keratins could take at the forefront of biomaterials development (Various Authors, Kogyo Zairyo 1993; 41 (15) Special issue 2:106-9).
[0012] Taken together, the aforementioned body of published work is illustrative of the unique chemical, physical, and biological properties of keratins. However, there remains a need to create optimal fractionations of keratins that have superior biomedical activity.
SUMMARY OF THE INVENTION
[0013] The invention provides methods of making charged (i.e. acidic and basic) keratins by separating one from the other, e.g., by chromatography, and optionally further processing or purifying the retained fraction or fractions. In some embodiments, the keratins fractionated based on acidity consist essentially of alpha keratoses, gamma keratoses, or mixtures thereof. In other embodiments, the keratins fractionated consist essentially of alpha kerateines, gamma kerateines, or mixtures thereof.
[0014] Another aspect of the present invention is an implantable biomedical device, comprising: a substrate and a keratin derivative on the substrate, wherein the keratin derivative is present in an amount effective to reduce cell and tissue adhesion to the substrate. In some embodiments the keratin derivative comprises, consists of or consists essentially of basic alpha keratose, basic gamma keratose, basic alpha kerateine, basic gamma kerateine, or combinations thereof.
[0015] A further aspect of the present invention is an implantable anti-adhesive tissue barrier, comprising: a solid, physiologically acceptable substrate; and a keratin derivative on the substrate. In some embodiments the keratin derivative comprises, consists of or consists essentially of basic alpha keratose, basic gamma keratose, basic alpha kerateine, basic gamma kerateine, or combinations thereof.
[0016] Yet another aspect of the present invention is a method of treating blood coagulation in a subject in need thereof, comprising administering a keratin derivative to said subject in an amount effective to inhibit blood coagulation in said subject, wherein said keratin derivative consists essentially of basic keratose, basic kerateine, or combinations thereof.
[0017] Another aspect of the present invention is the use of a keratin derivative as described herein for the preparation of a composition or medicament for carrying out a method of treatment as described herein, or for making an article of manufacture as described herein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The unique properties of subfamilies of keratins can be revealed and utilized through more sophisticated means of purification.
[0019] “Subjects” (or “patients”) to be treated with the methods and compositions described herein include both human subjects and animal subjects (particularly other mammalian subjects such as dogs, cats, horses, monkeys, etc.) for veterinary purposes. Human subjects are particularly preferred. The subjects may be male or female and may be any age, including neonate, infant, juvenile, adolescent, adult, and geriatric subjects.
[0020] The disclosures of all United States patent references cited herein are to be incorporated herein by reference.
[0021] The ability of extracted keratin solutions to spontaneously self-assemble at the micron scale was published in two papers in 1986 and 1987 (Thomas H et al., Int J Biol Macromol 1986; 8:258-64; van de Löcht M, Melliand Textilberichte 1987; 10:780-6). This phenomenon is not surprising given the highly controlled superstructure whence hair keratins are obtained. When processed correctly, this ability to self-assemble can be preserved and used to create regular architectures on a size scale conducive to cellular infiltration. When keratins are hydrolyzed (e.g., with acids or bases), their molecular weight is reduced and they lose the ability to self-assemble. Therefore, processing conditions that minimize hydrolysis are preferred.
[0022] This ability to self-assemble is a particularly useful characteristic for tissue engineering scaffolds for two reasons. First, self-assembly results in a highly regular structure with reproducible architectures, dimensionality, and porosity. Second, the fact that these architectures form of their own accord under benign conditions allows for the incorporation of cells as the matrix is formed. These two features are critically important to any system that attempts to mimic the native extracellular matrix (ECM).
[0023] Cellular recognition is also an important characteristic of biomaterials that seek to mimic the ECM. Such recognition is facilitated by the binding of cell surface integrins to specific amino acid motifs presented by the constituent ECM proteins. Predominant proteins include collagen and fibronectin, both of which have been extensively studied with regard to cell binding. Both proteins contain several regions that support attachment by a wide variety of cell types. It has been shown that in addition to the widely know Arginine-Glycine-Aspartic Acid (RGD) motif, the “X”-Aspartic Acid-“Y” motif on fibronectin is also recognized by the integrin α4β1, where X equals Glycine, Leucine, or Glutamic Acid, and Y equals Serine or Valine. Keratin-biomaterials derived from human hair contain these same binding motifs. A search of the NCBI protein database revealed sequences for 71 discrete, unique human hair keratin proteins. Of these, 55 are from the high molecular weight, low sulfur, alpha-helical family. This group of proteins is often referred to as the alpha-keratins and is responsible for imparting toughness to human hair fibers. These alpha-keratins have molecular weights greater than 40 kDa and an average cysteine (the main amino acid responsible for inter- and intramolecular protein bonding) content of 4.8 mole percent. Moreover, analysis of the amino acid sequences of these alpha keratin proteins showed that 78% contain at least one fibronectin-like integrin receptor binding motif, and 25% contain at least two or more. Two recent papers have highlighted the fact that these binding sites are likely present on the surface of keratin biomaterials by demonstrating excellent cell adhesion onto processed keratin foams (Tachibana A et al., J Biotech 2002; 93:165-70; Tachibana A et al., Biomaterials 2005; 26(3):297-302).
[0024] Other examples of natural polymers that may be utilized in a similar fashion to the disclosed keratin preparations include, but are not limited to, collagen, gelatin, fibronectin, vitronectin, laminin, fibrin, mucin, elastin, nidogen (entactin), proteoglycans, etc. (See, e.g., U.S. Pat. No. 5,691,203 to Katsuen et al.).
[0025] There are two theories for the biological activity of human hair extracts. The first is that the human hair keratins (“HHKs”) themselves are biologically active. Over 70 human hair keratins are known and their cDNA-derived sequences published. However, the full compliment of HHKs is unknown and estimates of over 100 have been proposed (Gillespie J M, The structural proteins of hair: isolation characterization, and regulation of biosynthesis. Goldsmith L A (editor), Biochemistry and physiology of the skin (1983), Oxford University Press. New York; 475-510). Within the complete range of HHKs are a small number that have been shown to participate in wound contracture and cell migration (Martin, P, Science 1997; 276:75-81). In particular, keratins K-6 and K-16 are expressed in the epidermis during wound healing and are also found in the outer root sheath of the hair follicle (Bowden P E, Molecular Aspects of Dermatology (1993), John Wiley & Sons, Inc., Chichester: 19-54). The presence of these HHKs in extracts of human hair, and their subsequent dosing directly into a wound bed, may be responsible for “shortcutting” the otherwise lengthy process of differentiation, migration, and proliferation, or for alleviating some biochemical deficiency, thereby accelerating the tissue repair and regeneration process.
[0026] It has been known for more than a decade that growth factors such as bone morphogenetic protein-4 (BMP-4) and other members of the transforming growth factors (TGF-β) superfamily are present in developing hair follicles (Jones C M et al., Development 1991; 111:531-42; Lyons K M et al., Development 1990; 109:833-44; Blessings M et al., Genes and Develop 1993; 7:204-15). In fact, more than 30 growth factors and cytokines are involved in the growth of a cycling hair follicle (Hardy M H, Trends Genet 1992; 8(2):55-61; Stenn K S et al., J Dermato Sci 1994; 7S:S109-24; Rogers G E, Int J Dev Biol 2004; 48(2-3):163-70). Many of these molecules have a pivotal role in the regeneration of a variety of tissues. It is highly probable that a number of growth factors become entrained within human hair when cytokines bind to stem cells residing in the bulge region of the hair follicle (Panteleyev A A et al., J Cell Sci 2001; 114:3419-31). These growth factors would most certainly be extracted along with the keratins from end-cut human hair. This observation is not without precedent, as it has previously been shown that many different types of growth factors are present in the extracts of various tissues, and that their activity is maintained even after chemical extraction. Observations such as these show mounting evidence that a number of growth factors may be present in end-cut human hair, and that the keratins may be acting as a highly effective delivery matrix of, inter alia, these growth factors.
[0027] Keratins are a family of proteins found in the hair, skin, and other tissues of vertebrates. Hair is a unique source of human keratins because it is one of the few human tissues that is readily available and inexpensive. Although other sources of keratins are acceptable feedstocks for the present invention, (e.g. wool, fur, horns, hooves, beaks, feathers, scales, and the like), human hair is preferred for use with human subjects because of its biocompatibility.
[0028] Keratins can be extracted from human hair fibers by oxidation or reduction using methods that have been published in the art (See, e.g., Crewther W G et al. The chemistry of keratins, in Advances in protein chemistry 1965; 20:191-346). These methods typically employ a two-step process whereby the crosslinked structure of keratins is broken down by either oxidation or reduction. In these reactions, the disulfide bonds in cysteine amino acid residues are cleaved, rendering the keratins soluble (Scheme 1). The cuticle is essentially unaffected by this treatment, so the majority of the keratins remain trapped within the cuticle's protective structure. In order to extract these keratins, a second step using a denaturing solution must be employed. Alternatively, in the case of reduction reactions, these steps can be combined. Denaturing solutions known in the art include urea, transition metal hydroxides, surfactant solutions, and combinations thereof. Preferred methods use aqueous solutions of tris in concentrations between 0.1 and 1.0 M, and urea solutions between 0.1 and 10M, for oxidation and reduction reactions, respectively.
[0000]
[0029] If one employs an oxidative treatment, the resulting keratins are referred to as “keratoses.”. If a reductive treatment is used, the resulting keratins are referred to as “kerateines” (See Scheme 1)
[0030] Crude extracts of keratins, regardless of redox state, can be further refined into “gamma” and “alpha” fractions, e.g., by isoelectric precipitation. High molecular weight keratins, or “alpha keratins,” (alpha helical), are thought to derive from the microfibrillar regions of the hair follicle, and typically range in molecular weight from about 40-85 kiloDaltons. Low molecular weight keratins, or “gamma keratins,” (globular), are thought to derive from the extracellular matrix regions of the hair follicle, and typically range in molecular weight from about 10-15 kiloDaltons. (See Crewther W G et al. The chemistry of keratins, in Advances in Protein Chemistry 1965; 20:191-346)
[0031] Even though alpha and gamma keratins possess unique properties, the properties of subfamilies of both alpha and gamma keratins can only be revealed through more sophisticated means of purification. For example, keratins may be fractionated into “acidic” and “basic” protein fractions. A preferred method of fractionation is ion exchange chromatography. These fractions possess unique properties, such as their differential effects on blood cell aggregation (See Table 1 below; See also: U.S. Patent Application Publication No. 2006/0051732).
[0032] “Keratin derivative” as used herein refers to any keratin fractionation, derivative, subfamily, etc., or mixtures thereof, alone or in combination with other keratin derivatives or other ingredients, including but not limited to alpha keratose, gamma keratose, alpha kerateine, gamma kerateine, meta keratin, keratin intermediate filaments, and combinations thereof, including the acidic and basic constituents thereof unless specified otherwise, along with variations thereof that will be apparent to persons skilled in the art in view of the present disclosure. In some embodiments, the keratin derivative comprises, consists or consists essentially of a particular fraction or subfraction of keratin. The derivative may comprise, consist or consist essentially of at least 80, 90, 95 or 99 percent by weight of said fraction or subfraction (or more).
[0033] In some embodiments, the keratin derivative comprises, consists of, or consists essentially of acidic alpha keratose.
[0034] In some embodiments, the keratin derivative comprises, consists of or consists essentially of alpha keratose, where the alpha keratose comprises, consists of or consists essentially of at least 80, 90, 95 or 99 percent by weight of acidic alpha keratose (or more), and where the alpha keratose comprises, consists of, or consists essentially of not more than 20, 10, 5 or 1 percent by weight of basic alpha keratose (or less).
[0035] In some embodiments, the keratin derivative comprises, consists of, or consists essentially of basic alpha keratose.
[0036] In some embodiments, the keratin derivative comprises, consists of or consists essentially of alpha keratose, where the alpha keratose comprises, consists of or consists essentially of at least 80, 90, 95 or 99 percent by weight of basic alpha keratose (or more), and where the alpha keratose comprises, consists of or consists essentially of not more than 20, 10, 5 or 1 percent by weight of acidic alpha keratose (or less).
[0037] In some embodiments, the keratin derivative comprises, consists of, or consists essentially of acidic alpha kerateine.
[0038] In some embodiments, the keratin derivative comprises, consists of or consists essentially of alpha kerateine, where the alpha kerateine comprises, consists of or consists essentially of at least 80, 90, 95 or 99 percent by weight of acidic alpha kerateine (or more), and where the alpha kerateine comprises, consists of or consists essentially of not more than 20, 10, 5 or 1 percent by weight of basic alpha kerateine (or less).
[0039] In some embodiments, the keratin derivative comprises, consists of, or consists essentially of basic alpha kerateine.
[0040] In some embodiments, the keratin derivative comprises, consists of or consists essentially of alpha kerateine, where the alpha kerateine comprises, consists of or consists essentially of at least 80, 90, 95 or 99 percent by weight of basic alpha kerateine (or more), and where the alpha kerateine comprises, consists of or consists essentially of not more than 20, 10, 5 or 1 percent by weight of acidic alpha kerateine (or less).
[0041] In some embodiments, the keratin derivative comprises, consists of or consists essentially of unfractionated alpha+gamma-kerateines. In some embodiments, the keratin derivative comprises, consists of or consists essentially of acidic alpha+gamma-kerateines. In some embodiments, the keratin derivative comprises, consists of or consists essentially of basic alpha+gamma-kerateines.
[0042] In some embodiments, the keratin derivative comprises, consists of or consists essentially of unfractionated alpha+gamma-keratose. In some embodiments, the keratin derivative comprises, consists of or consists essentially of acidic alpha+gamma-keratose. In some embodiments, the keratin derivative comprises, consists of or consists essentially of basic alpha+gamma-keratose.
[0043] In some embodiments, the keratin derivative comprises, consists of or consists essentially of unfractionated beta-keratose (e.g., derived from cuticle). In some embodiments, the keratin derivative comprises, consists of or consists essentially of basic beta-keratose. In some embodiments, the keratin derivative comprises, consists of or consists essentially of acidic beta-keratose.
[0044] The basic alpha keratose is preferably produced by separating basic alpha keratose from a mixture comprising acidic and basic alpha keratose, e.g., by ion exchange chromatography, and optionally the basic alpha keratose has an average molecular weight of from 10 to 100 or 200 kiloDaltons. More preferably, the average molecular weight is from 30 or 40 to 90 or 100 kiloDaltons. Optionally but preferably the process further comprises the steps of re-disolving said basic alpha-keratose in a denaturing and/or buffering solution, optionally in the presence of a chelating agent to complex trace metals, and then re-precipitating the basic alpha keratose from the denaturing solution. It will be appreciated that the composition preferably contains not more than 5, 2, 1, or 0.1 percent by weight of acidic alpha keratose, or less.
[0045] The acidic alpha keratose is preferably produced by a reciprocal of the foregoing technique; that is, by separating and retaining acidic alpha keratose from a mixture of acidic and basic alpha keratose, e.g., by ion exchange chromatography, and optionally the acidic alpha keratose has an average molecular weight of from 10 to 100 or 200 kiloDaltons. More preferably, the average molecular weight is from 30 or 40 to 90 or 100 kiloDaltons. Optionally but preferably the process further comprises the steps of re-dissolving said acidic alpha-keratose in a denaturing solution and/or buffering solution, optionally in the presence of a chelating agent to complex trace metals, and then re-precipitating the basic alpha keratose from the denaturing solution. It will be appreciated that the composition preferably contains not more than 5, 2, 1, or 0.1 percent by weight of basic alpha keratose, or less.
[0046] Basic and acidic fractions of other keratoses can be prepared in like manner as described above for basic and acidic alpha keratose.
[0047] The basic alpha kerateine is preferably produced by separating basic alpha kerateine from a mixture of acidic and basic alpha kerateine, e.g., by ion exchange chromatography, and optionally the basic alpha kerateine has an average molecular weight of from 10 to 100 or 200 kiloDaltons. More preferably, the average molecular weight is from 30 or 40 to 90 or 100 kiloDaltons. Optionally but preferably the process further comprises the steps of re-dissolving said basic alpha-kerateine in a denaturing and/or buffering solution, optionally in the presence of a chelating agent to complex trace metals, and then re-precipitating the basic alpha kerateine from the denaturing solution. It will be appreciated that the composition preferably contains not more than 5, 2, 1, or 0.1 percent by weight of acidic alpha kerateine, or less.
[0048] The acidic alpha kerateine is preferably produced by a reciprocal of the foregoing technique: that is, by separating and retaining acidic alpha kerateine from a mixture of acidic and basic alpha kerateine, e.g., by ion exchange chromatography, and optionally the acidic alpha kerateine has an average molecular weight of from 10 to 100 or 200 kiloDaltons. Optionally but preferably the process further comprises the steps of re-dissolving said acidic alpha-kerateine in a denaturing and/or buffering solution), optionally in the presence of a chelating agent to complex trace metals, and then re-precipitating the basic alpha kerateine from the denaturing solution. It will be appreciated that the composition preferably contains not more than 5, 2, 1, or 0.1 percent by weight of basic alpha kerateine, or less.
[0049] Basic and acidic fractions of other kerateines can be prepared in like manner as described above for basic and acidic alpha kerateine.
[0050] Keratin materials are derived from any suitable source, including, but not limited to, wool and human hair. In one embodiment keratin is derived from end-cut human hair, obtained from barbershops and salons. The material is washed in hot water and mild detergent, dried, and extracted with a nonpolar organic solvent (typically hexane or ether) to remove residual oil prior to use.
[0051] Keratoses. Keratose fractions are obtained by any suitable technique. In one embodiment they are obtained using the method of Alexander and coworkers (P. Alexander et al., Biochem. J. 46, 27-32 (1950)). Basically, the hair is reacted with an aqueous solution of peracetic acid at concentrations of less than ten percent at room temperature for 24 hours. The solution is filtered and the alpha-keratose fraction precipitated by addition of mineral acid to a pH of approximately 4. The alpha-keratose is separated by filtration, washed with additional acid, followed by dehydration with alcohol, and then freeze dried. Increased purity can be achieved by re-dissolving the keratose in a denaturing solution such as 7M urea, aqueous ammonium hydroxide solution, or 20 mM tris base buffer solution (e.g., Trizma® base), re-precipitating, re-dissolving, dialyzing against deionized water, and re-precipitating at pH 4.
[0052] A preferred method for the production of keratoses is by oxidation with hydrogen peroxide, peracetic acid, or performic acid. A most preferred oxidant is peracetic acid. Preferred concentrations range from 1 to 10 weight/volume percent (w/v %), the most preferred being approximately 2 w/v %. Those skilled in the art will recognize that slight modifications to the concentration can be made to effect varying degrees of oxidation, with concomitant alterations in reaction time, temperature, and liquid to solid ratio. It has also been discussed by Crewther et al. that performic acid offers the advantage of minimal peptide bond cleavage compared to peracetic acid. However, peractic acid offers the advantages of cost and availability. A preferred oxidation temperature is between 0 and 100 degrees Celsius (° C.). A most preferred oxidation temperature is 37° C. A preferred oxidation time is between 0.5 and 24 hours. A most preferred oxidation time is 12 hours. A preferred liquid to solid ratio is from 5 to 100:1. A most preferred ratio is 20:1. After oxidation, the hair is rinsed free of residual oxidant using a copious amount of distilled water.
[0053] The keratoses can be extracted from the oxidized hair using an aqueous solution of a denaturing agent. Protein denaturants are well known in the art, but preferred solutions include urea, transition metal hydroxides (e.g. sodium and potassium hydroxide), ammonium hydroxide, and tris(hydroxymethyl)aminomethane (tris base). A preferred solution is Trizma® base (a brand of tris base) in the concentration range from 0.01 to 1M. A most preferred concentration is 0.1M. Those skilled in the art will recognize that slight modifications to the concentration can be made to effect varying degrees of extraction, with concomitant alterations in reaction time, temperature, and liquid to solid ratio. A preferred extraction temperature is between 0 and 100 degrees Celsius. A most preferred extraction-temperature is 37° C. A preferred extraction time is between 0.5 and 24 hours. A most preferred extraction time is 3 hours. A preferred liquid to solid ratio is from 5 to 100:1. A most preferred ratio is 40:1. Additional yield can be achieved with subsequent extractions with dilute solutions of tris base or deionized (DI) water. After extraction, the residual solids are removed from solution by centrifugation and/or filtration.
[0054] The crude extract can be isolated by first neutralizing the solution to a pH between 7.0 and 7.4. A most preferred pH is 7.4. Residual denaturing agent is removed by dialysis against DI water. Concentration of the dialysis retentate is followed by lyophilization or spray drying, resulting in a dry powder mixture of both gamma- and alpha-keratose. Alternately, alpha-keratose is isolated from the extract solution by dropwise addition of acid until the pH of the solution reaches approximately 4.2. Preferred acids include sulfuric, hydrochloric, and acetic. A most preferred acid is concentrated hydrochloric acid. Precipitation of the alpha fraction begins at around pH 6.0 and continues until approximately 4.2. Fractional precipitation can be utilized to isolate different ranges of protein with different isoelectric properties. Solid alpha-keratose can be recovered by centrifugation or filtration.
[0055] The alpha keratose can be further purified by re-dissolving the solids in a denaturing solution. The same denaturing solutions as those utilized for extraction can be used, however a preferred denaturing solution is tris base. Ethylene diamine tetraacetic acid (EDTA) can be added to complex and remove trace metals found in the hair. A preferred denaturing solution is 20 mM tris base with 20 mM EDTA or DI water with 20 mM EDTA. If the presence of trace metals is not detrimental to the intended application, the EDTA can be omitted. The alpha-keratose is re-precipitated from this solution by dropwise addition of hydrochloric acid to a final pH of approximately 4.2. Isolation of the solid is by centrifugation or filtration. This process can be repeated several times to further purify the alpha-keratose.
[0056] The gamma keratose fraction remains in solution at pH 4 and is isolated by addition to a water-miscible organic solvent such as alcohol, followed by filtration, dehydrated with additional alcohol, and freeze dried. Increased purity can be achieved by re-dissolving the keratose in a denaturing solution such as 7M urea, aqueous ammonium hydroxide solution, or 20 mM tris buffer solution, reducing the pH to 4 by addition of a mineral acid, removing any solids that form, neutralizing the supernatant, re-precipitating the protein with alcohol, re-dissolving, dialyzing against deionized water, and re-precipitating by addition to alcohol. The amount of alcohol consumed in these steps can be minimized by first concentrating the keratose solution by distillation.
[0057] After removal of the alpha keratose, the concentration of gamma keratose from a typical extraction solution is approximately 1-2%. The gamma keratose fraction can be isolated by addition to a water-miscible non-solvent. To effect precipitation, the gamma-keratose solution can be concentrated by evaporation of excess water. This solution can be concentrated to approximately 10-20% by removal of 90% of the water. This can be done using vacuum distillation or by falling film evaporation. After concentration, the gamma-keratose solution is added dropwise to an excess of cold non-solvent. Suitable non-solvents include ethanol, methanol, acetone, and the like. A most preferred non-solvent is ethanol. A most preferred method is to concentrate the gamma keratose solution to approximately 10 w/v % protein and add it dropwise to an 8-fold excess of cold ethanol. The precipitated gamma keratose can be isolated by centrifugation or filtration and dried. Suitable methods for drying include freeze drying (lyophilization), air drying, vacuum drying, or spray drying. A most preferred method is freeze drying.
[0058] Kerateines. Kerateine fractions can be obtained using a combination of the methods of Bradbury and Chapman (J. Bradbury et al., Aust. J. Biol. Sci. 17, 960-72 (1964)) and Goddard and Michaelis (D. Goddard et al., J. Biol. Chem. 106, 605-14 (1934)). Essentially, the cuticle of the hair fibers is removed ultrasonically in order to avoid excessive hydrolysis and allow efficient reduction of cortical disulfide bonds in a second step. The hair is placed in a solution of dichloroacetic acid and subjected to treatment with an ultrasonic probe. Further refinements of this method indicate that conditions using 80% dichloroacetic acid, solid to liquid of 1:16, and an ultrasonic power of 180 Watts are optimal (H. Ando et al., Sen'i Gakkaishi 31(3), T81-85 (1975)). Solid fragments are removed from solution by filtration, rinsed and air dried, followed by sieving to isolate the hair fibers from removed cuticle cells.
[0059] In some embodiments, following ultrasonic removal of the cuticle, alpha- and gamma-kerateines are obtained by reaction of the denuded fibers with mercaptoethanol. Specifically, a low hydrolysis method is used at acidic pH (E. Thompson et al., Aust. J. Biol. Sci. 15, 757-68 (1962)). In a typical reaction, hair is extracted for 24 hours with 4M mercaptoethanol that has been adjusted to pH 5 by addition of a small amount of potassium hydroxide in deoxygenated water containing 0.02M acetate buffer and 0.001M surfactant.
[0060] The solution is filtered and the alpha-kerateine fraction precipitated by addition of mineral acid to a pH of approximately 4. The alpha-kerateine is separated by filtration, washed with additional acid, followed by dehydration with alcohol, and then dried under vacuum. Increased purity is achieved by re-dissolving the kerateine in a denaturing solution such as 7M urea, aqueous ammonium hydroxide solution, or 20 mM tris buffer solution, re-precipitating, re-dissolving, dialyzing against deionized water, and re-precipitating at pH 4.
[0061] The gamma kerateine fraction remains in solution at pH 4 and is isolated by addition to a water-miscible organic solvent such as alcohol, followed by filtration, dehydrated with additional alcohol, and dried under vacuum. Increased purity can be achieved by re-dissolving the kerateine in a denaturing solution such as 7M urea, aqueous ammonium hydroxide solution, or 20 mM tris buffer solution, reducing the pH to 4 by addition of a mineral acid, removing any solids that form, neutralizing the supernatant, re-precipitating the protein with alcohol, re-dissolving, dialyzing against deionized water, and reprecipitating by addition to alcohol. The amount of alcohol consumed in these steps can be minimized by first concentrating the keratin solution by distillation.
[0062] In an alternate method, the kerateine fractions are obtained by reacting the hair with an aqueous solution of sodium thioglycolate.
[0063] A preferred method for the production of kerateines is by reduction of the hair with thioglycolic acid or beta-mercaptoethanol. A most preferred reductant is thioglycolic acid (TGA). Preferred concentrations range from 1 to 10M, the most preferred being approximately 1.0M. Those skilled in the art will recognize that slight modifications to the concentration can be made to effect varying degrees of reduction, with concomitant alterations in pH, reaction time, temperature, and liquid to solid ratio. A preferred pH is between 9 and 11. A most preferred pH is 10.2. The pH of the reduction solution is altered by addition of base. Preferred bases include transition metal hydroxides, sodium hydroxide, and ammonium hydroxide. A most preferred base is sodium hydroxide. The pH adjustment is effected by dropwise addition of a saturated solution of sodium hydroxide in water to the reductant solution. A preferred reduction temperature is between 0 and 100° C. A most preferred reduction temperature is 37° C. A preferred reduction time is between 0.5 and 24 hours. A most preferred reduction time is 12 hours. A preferred liquid to solid ratio is from 5 to 100:1. A most preferred ratio is 20:1. Unlike the previously described oxidation reaction, reduction is carried out at basic pH. That being the case, keratins are highly soluble in the reduction media and are expected to be extracted. The reduction solution is therefore combined with the subsequent extraction solutions and processed accordingly.
[0064] Reduced keratins are not as hydrophilic as their oxidized counterparts. As such, reduced hair fibers will not swell and split open as will oxidized hair, resulting in relatively lower yields. Another factor affecting the kinetics of the reduction/extraction process is the relative solubility of kerateines. The relative solubility rankings in water is gamma-keratose>alpha-keratose>gamma-kerateine>alpha-kerateine from most to least soluble. Consequently, extraction yields from reduced hair fibers are not as high. This being the case, subsequent extractions are conducted with additional reductant plus denaturing agent solutions. Preferred solutions for subsequent extractions include TGA plus urea, TGA plus tris base, or TGA plus sodium hydroxide. After extraction, crude fractions of alpha- and gamma-kerateine can be isolated using the procedures described for keratoses. However, precipitates of gamma- and alpha-kerateine re-form their cystine crosslinks upon exposure to oxygen. Precipitates must therefore be re-dissolved quickly to avoid insolubility during the purification stages, or precipitated in the absence of oxygen.
[0065] Residual reductant and denaturing agents can be removed from solution by dialysis. Typical dialysis conditions are 1 to 2% solution of kerateines dialyzed against DI water for 24 to 72 hours. Those skilled in the art will recognize that other methods exist for the removal of low molecular weight contaminants in addition to dialysis (e.g. microfiltration, chromatography, and the like). The use of tris base is only required for initial solubilization of the kerateines. Once dissolved, the kerateines are stable in solution without the denaturing agent. Therefore, the denaturing agent can be removed without the resultant precipitation of kerateines, so long as the pH remains at or above neutrality. The final concentration of kerateines in these purified solutions can be adjusted by the addition/removal of water.
[0066] Regardless of the form of the keratin (i.e. keratoses or kerateines), several different approaches to further purification can be employed to keratin solutions. Care must be taken, however, to choose techniques that lend themselves to keratin's unique solubility characteristics. One of the most simple separation technologies is isoelectric precipitation. In this method, proteins of differing isoelectric point can be isolated by adjusting the pH of the solution and removing the precipitated material. In the case of keratins, both gamma- and alpha-forms are soluble at pH >6.0. As the pH falls below 6, however, alpha-keratins begin to precipitate. Keratin fractions can be isolated by stopping the precipitation at a given pH and separating the precipitate by centrifugation and/or filtration. At a pH of approximately 4.2, essentially all of the alpha-keratin will have been precipitated. These separate fractions can be re-dissolved in water at neutral pH, dialyzed, concentrated, and reduced to powders by lyophilization or spray drying. However, kerateine fractions must be stored in the absence of oxygen or in dilute solution to avoid crosslinking.
[0067] Another general method for separating keratins is by chromatography. Several types of chromatography can be employed to fractionate keratin solutions including size exclusion or gel filtration chromatography, affinity chromatography, isoelectric focusing, gel electrophoresis, ion exchange chromatography, and immunoaffinity chromatography. These techniques are well known in the art and are capable of separating compounds, including proteins, by the characteristics of molecular weight, chemical functionality, isoelectric point, charge, or interactions with specific antibodies, and can be used alone or in any combination to effect high degrees of separation and resulting purity.
[0068] A preferred purification method is ion exchange (IEx) chromatography. IEx chromatography is particularly suited to protein separation owning to the amphiphilic nature of proteins in general and keratins in particular. Depending on the starting pH of the solution, and the desired fraction slated for retention, either cationic or anionic IEx (CIEx or AIEx, respectively) techniques can be used. For example, at a pH of 6 and above, both gamma- and alpha-keratins are soluble and above their isoelectric points. As such, they are anionic and can be bound to an anionic exchange resin. However, it has been discovered that a sub-fraction of keratins does not bind to a weakly anionic exchange resin and instead passes through a column packed with such resin. A preferred solution for AIEx chromatography is purified or fractionated keratin, isolated as described previously, in purified water at a concentration between 0 and 5 weight/volume %. A preferred concentration is between 0 and 4 w/v %. A most preferred concentration is approximately 2 w/v %. It is preferred to keep the ionic strength of said solution initially quite low to facilitate binding to the AIEx column. This is achieved by using a minimal amount of acid to titrate a purified water solution of the keratin to between pH 6 and 7. A most preferred pH is 6. This solution can be loaded onto an AIEx column such as DEAE-Sepharose® resin or Q-Sepharose® resin columns. A preferred column resin is DEAE-Sepharose® resin. The solution that passes through the column can be collected and further processed as described previously to isolate a fraction of acidic keratin powder.
[0069] In some embodiments the activity of the keratin matrix is enhanced by using an AIEx column to produce the keratin that may be useful for, inter alia, promoting cell adhesion. Without wishing to be bound to any particular theory, it is envisioned that the fraction that passes through an anionic column, i.e. acidic keratin, promotes cell adhesion.
[0070] Another fraction binds readily, and can be washed off the column using salting techniques known in the art. A preferred elution medium is sodium chloride solution. A preferred concentration of sodium chloride is between 0.1 and 2M. A most preferred concentration is 2M. The pH of the solution is preferred to be between 6 and 12. A most preferred pH is 12. In order to maintain stable pH during the elution process, a buffer salt can be added. A preferred buffer salt is Trizma® base. Those skilled in the art will recognize that slight modifications to the salt concentration and pH can be made to effect the elution of keratin fractions with differing properties. It is also possible to use different salt concentrations and pH's in sequence, or employ the use of salt and/or pH gradients to produce different fractions. Regardless of the approach taken, however, the column eluent can be collected and further processed as described previously to isolate fractions of basic keratin powders.
[0071] A complimentary procedure is also feasible using CIEx techniques. Namely, the keratin solution can be added to a cation exchange resin such as SP Sepharose® resin (strongly cationic) or CM Sepharose® resin (weakly cationic), and the basic fraction collected with the pass through. The retained acid keratin fraction can be isolated by salting as previously described.
[0072] Meta keratins. Meta keratins are synthesized from both the alpha and gamma fractions of kerateine using substantially the same procedures. Basically, the kerateine is dissolved in a denaturing solution such as 7M urea, aqueous ammonium hydroxide solution, or 20 mM tris buffer solution. Pure oxygen is bubbled through the solution to initiate oxidative coupling reactions of cysteine groups. The progress of the reaction is monitored by an increase in molecular weight as measured using SDS-PAGE. Oxygen is continually bubbled through the reaction solution until a doubling or tripling of molecular weight is achieved. The pH of the denaturing solution can be adjusted to neutrality to avoid hydrolysis of the proteins by addition of mineral acid.
[0073] Keratin intermediate filaments. IFs of human hair fibers are obtained using the method of Thomas and coworkers (H. Thomas et al., Int. J. Biol. Macromol. 8, 258-64 (1986)). This is essentially a chemical etching method that reacts away the keratin matrix that serves to “glue” the IFs in place, thereby leaving the IFs behind. In a typical extraction process, swelling of the cuticle and sulfitolysis of matrix proteins is achieved using 0.2M Na 2 SO 3 , 0.1M Na 2 O 6 S 4 in 8M urea and 0.1M Tris-HCl buffer at pH 9. The extraction proceeds at room temperature for 24 hours. After concentrating, the dissolved matrix keratins and IFs are precipitated by addition of zinc acetate solution to a pH of approximately 6. The IFs are then separated from the matrix keratins by dialysis against 0.05M tetraborate solution. Increased purity is obtained by precipitating the dialyzed solution with zinc acetate, redissolving the IFs in sodium citrate, dialyzing against distilled water, and then freeze drying the sample.
[0074] Further discussion of keratin preparations are found in U.S. Patent Application Publication 2006/0051732 (Van Dyke), which is incorporated by reference herein.
[0075] Formulations. Dry powders may be formed of keratin derivatives as described above in accordance with known techniques such as freeze drying (lyophilization). In some embodiments, compositions of the invention may be produced by mixing such a dry powder composition form with an aqueous solution to produce a composition comprising an electrolyte solution having said keratin derivative solubilized therein. The mixing step can be carried out at any suitable temperature, typically room temperature, and can be carried out by any suitable technique such as stirring, shaking, agitation, etc. The salts and other constituent ingredients of the electrolyte solution (e.g., all ingredients except the keratin derivative and the water) may be contained entirely in the dry powder, entirely within the aqueous composition, or may be distributed between the dry powder and the aqueous composition. For example, in some embodiments, at least a portion of the constituents of the electrolyte solution is contained in the dry powder.
[0076] The formation of a matrix comprising keratin materials such as described above can be carried out in accordance with techniques long established in the field or variations thereof that will be apparent to those skilled in the art. In some embodiments, the keratin preparation is dried and rehydrated prior to use. See, e.g., U.S. Pat. No. 2,413,983 to Lustig et al., U.S. Pat. Nos. 2,236,921 to Schollkipf et al., and 3,464,825 to Anker. In preferred embodiments, the matrix, or hydrogel, is formed by re-hydration of the lyophilized material with a suitable solvent, such as water or phosphate buffered saline (PBS). The gel can be sterilized, e.g., by γ-irradiation (806 krad) using a Co60 source. Other suitable methods of forming keratin matrices include, but are not limited to, those found in U.S. Pat. Nos. 6,270,793 (Van Dyke et al.), 6,274,155 (Van Dyke et al.), 6,316,598 (Van Dyke et al.), 6,461,628 (Blanchard et al.), 6,544,548 (Siller-Jackson et al.), and 7,01,987 (Van Dyke).
[0077] In some composition embodiments, the keratin derivatives (particularly alpha and/or gamma kerateine and alpha and/or gamma keratose) have an average molecular weight of from about 10 to 70 or 85 or 100 kiloDaltons. Other keratin derivatives, particularly meta-keratins, may have higher average molecular weights, e.g., up to 200 or 300 kiloDaltons. In general, the keratin derivative (this term including combinations of derivatives) may be included in the composition in an amount of from about 0.1, 0.5 or 1 percent by weight up to 3, 4, 5, or 10 percent by weight. The composition when mixed preferably has a viscosity of about 1 or 1.5 to 4, 8, 10 or 20 centipoise. Viscosity at any concentration can be modulated by changing the ratio of alpha to gamma keratose.
[0078] The keratin derivative composition or formulation may optionally contain one or more active ingredients such as one or more growth factors (e.g., in an amount ranging from 0.0000001 to 1 or 5 percent by weight of the composition that comprises the keratin derivative(s)) to facilitate growth or healing, facilitate or inhibit coagulation, facilitate or inhibit cell or tissue adhesion, etc. Examples of suitable active ingredients include but are not limited to nerve growth factor, vascular endothelial growth factor, fibronectin, fibrin, laminin, acidic and basic fibroblast growth factors, testosterone, ganglioside GM-1, catalase, insulin-like growth factor-I (IGF-I), platelet-derived growth factor (PDGF), neuronal growth factor galectin-1, and combinations thereof. See, e.g., U.S. Pat. No. 6,506,727 to Hansson et al. and U.S. Pat. No. 6,890,531 to Horie et al.
[0079] As used herein, “growth factors” include molecules that promote the regeneration, growth and survival of tissue. Growth factors that are used in some embodiments of the present invention may be those naturally found in keratin extracts, or may be in the form of an additive, added to the keratin extracts or formed keratin matrices. Examples of growth factors include, but are not limited to, nerve growth factor (NGF) and other neurotrophins, platelet-derived growth factor (PDGF), erythropoietin (EPO), thrombopoietin (TPO), myostatin (GDF-8), growth differentiation factor-9 (GDF9), basic fibroblast growth factor (bFGF or FGF2), epidermal growth factor (EGF), hepatocyte growth factor CHGF), granulocyte-colony stimulating factor (G-CSF), and granulocyte-macrophage colony stimulating factor (GM-CSF). There are many structurally and evolutionarily related proteins that make up large families of growth factors, and there are numerous growth factor families, e.g., the neurotrophins (NGF, BDNF, and NT3). The neurotrophins are a family of molecules that promote the growth and survival of, inter alia, nervous tissue. Examples of neurotrophins include, but are not limited to, nerve growth factor (NGF), brain-derived neurotrophic factor (BDNF), neurotrophin 3 (NT-3), and neurotrophin 4 (NT-4). See U.S. Pat. Nos. 5,843,914 to Johnson, Jr. et al.; 5,488,099 to Persson et al.; 5,438,121 to Barde et al.; 5,235,043 to Collins et al.; and 6,005,081 to Burton et al.
[0080] For example, nerve growth factor (NGF) can be added to the keratin matrix composition in an amount effective to promote the regeneration, growth and survival of various tissues. The NGF is provided in concentrations ranging from 0.1 ng/mL to 1000 ng/mL. More preferably, NGF is provided in concentrations ranging from 1 ng/mL to 100 ng/mL, and most preferably 10 ng/mL to 100 ng/mL. See U.S. Pat. No. 6,063,757 to Urso.
[0081] Other examples of natural polymers that may be prepared and utilized in a similar fashion to the disclosed keratin preparations include, but are not limited to, collagen, gelatin, fibronectin, vitronectin and laminin (See, e.g., U.S. Pat. No. 5,691,203 to Katsuen et al.), with the necessary modifications apparent to those skilled in the art.
[0082] The composition is preferably sterile and non-pyrogenic. The composition may be provided preformed and aseptically packaged in a suitable container, such as a flexible polymeric bag or bottle, or a foil container, or may be provided as a kit of sterile dry powder in one container and sterile aqueous solution in a separate container for mixing just prior to use. When provided pre-formed and packaged in a sterile container the composition preferably has a shelf life of at least 4 or 6 months (up to 2 or 3 years or more) at room temperature, prior to substantial loss of viscosity (e.g., more than 10 or 20 percent) and/or substantial precipitation of the keratin derivative (e.g., settling detectable upon visual inspection).
[0083] Coatings and biomedical implants. As noted above, the present invention provides an implantable biomedical device, comprising: a substrate and a keratin derivative on the substrate, wherein the keratin derivative is present in an amount effective to reduce cell and/or tissue adhesion to the substrate. In some embodiments the keratin derivative comprises, consists of or consists essentially of basic alpha keratose, basic alpha kerateine, or combinations thereof.
[0084] The chemistry of keratins can be utilized to optimize the properties of keratin-based coatings. Alpha and gamma keratoses have inert sulfur residues. The oxidation reaction is a terminal step and results in the conversion of cystine residues into two non-reactive sulfonic acid residues. Kerateines, on the other hand, have labile sulfur residues. During the creation of the kerateines, cystine is converted to cysteine, which can be a source of further chemical modifications (See Scheme 1). One such useful reaction is oxidative sulfur-sulfur coupling. This reaction simply converts the cysteine back to cystine and reforms the crosslinks between proteins. This is a useful reaction for increasing the molecular weight of the gamma or alpha fraction of interest, which in turn will modify the bulk properties of the material. Increasing molecular weight influences material properties such as viscosity, dry film strength, gel strength, etc. Such reformed kerateines are referred to as meta keratins.
[0085] Meta keratins can be derived from the gamma or alpha fractions, or a combination of both. Oxidative re-crosslinking of the kerateines is affected by addition of an oxidizing agent such as peracetic acid or hydrogen peroxide. A preferred oxidizing agent is oxygen. This reaction can be accomplished simply by bubbling oxygen through the kerateine solution or by otherwise exposing the sample to air. Optimizing the molecular weight through the use of meta-keratins allows formulations to be optimized for a variety of properties including viscosity, film strength and elasticity, fiber strength, and hydrolytic susceptibility. Crosslinking in air works to improve biocompatibility by providing biomaterial with a minimum of foreign ingredients.
[0086] Any suitable substrate (typically a device intended for implanting into or inserting into a human or animal subject) may be coated or treated with keratin materials or keratin derivatives as described herein, including but not limited to grafts such as vascular grafts, vascular stents, catheters, leads, pacemakers, cardioverters, valves, fasteners or ports such as heart valves, etc.
[0087] The substrate may be formed from any suitable material, including but not limited to organic polymers (including stable polymers and biodegradable or bioerodable polymers), natural materials (e.g., collagen), metals (e.g., platinum, gold, stainless steel, etc.) inorganic materials such as silicon, glass, etc., and composites thereof.
[0088] Coating of the substrate may be carried out by any suitable means, such as spray coating, dip coating, or the like. In some embodiments, steps may be taken to couple or covalently couple the keratin to the substratem such as with a silane coupling agent, if so desired. The keratin derivative may be subsequently coated with another material, and/or other materials may be co-deposited with the keratin derivative, such as one or more additional active agents, stabilizers, coatings, etc.
[0089] Another aspect of the present invention is an implantable anti-adhesive tissue barrier, comprising: a solid, physiologically acceptable substrate (typically a sheet material, including but not limited to films, and woven and non-woven sheet materials formed from organic polymers or natural materials); and a keratin derivative on the substrate. In some embodiments the keratin derivative comprises, consists of or consists essentially of basic alpha keratose, basic alpha kerateine, or combinations thereof.
[0090] The present invention is explained in greater detail in the following non-limiting Examples.
Example 1
Crude Keratose Samples
[0091] Keratose fractions were obtained using a method based on that of Alexander and coworkers. However, the method was substantially modified to minimize hydrolysis of peptide bonds. Briefly, 50 grams of clean, dry hair that was collected from a local barber shop was reacted with 1000 mL of an aqueous solution of 2 w/v % peracetic acid (PAA) at room temperature for 12 hr. The oxidized hair was recovered using a 500 micron sieve, rinsed with copious amounts of DI water, and the excess water removed. Keratoses were extracted from the oxidized hair fibers with 1000 mL of 100 mM Trizma® base. After 3 hours, the hair was separated by sieve and the liquid neutralized by dropwise addition of hydrochloric acid (HCl). Additional keratoses were extracted from the remaining hair with two subsequent extractions using 1000 mL of 0.1M Trizma® base and 1000 mL of DI water, respectively. Each time the hair was separated by sieve and the liquid neutralized with HCl. All three extracts were combined, centrifuged, and any residual solid material removed by filtration. The combined extract was purified by tangential flow dialysis against DI water with a 1 KDa nominal low molecular weight cutoff membrane. The solution was concentrated and lyophilized to produce a crude keratose powder.
Example 2
Crude Kerateine Samples
[0092] Kerateine fractions were obtained using a modification of the method described by Goddard and Michaelis. Briefly; the hair was reacted with an aqueous solution of 1M TGA at 37° C. for 24 hours. The pH of the TGA solution had been adjusted to pH 10.2 by dropwise addition of saturated NaOH solution. The extract solution was filtered to remove the reduced hair fibers and retained. Additional keratin was extracted from the fibers by sequential extractions with 1000 mL of 100 mM TGA at pH 10.2 for 24 hours, 1000 mL of 10 mM TGA at pH 10.2 for 24 hours, and DI water at pH 10.2 for 24 hours. After each extraction, the solution was centrifuged, filtered, and added to the dialysis system. Eventually, all the extracts were combined and dialyzed against DI water with a 1 KDa nominal low molecular weight cutoff membrane. The solution was concentrated, titrated to pH 7, and stored at approximately 5% total protein concentration at 4° C. Alternately, the concentrated solution could be lyophilized and stored frozen and under nitrogen.
Example 3
Ion Exchange Chromatography
[0093] Just prior to fractionation, keratose samples were re-dissolved in ultrapure water and titrated to pH 6 by addition of dilute HCl solution. Kerateine samples were titrated to pH 6 by careful addition of dilute HCl solution as well. The samples were loaded onto a 200 mL flash chromatography column containing either DEAE-Sepharose (weakly anionic) or Q-Sepharose (strongly anionic) exchange resin (50-100 mesh; Sigma-Aldrich, Milwaukee, Wis.) with gentle pressure and the flow through collected (acidic keratin). A small volume of 10 mM Trizma® base (approximately 200 mL) at pH 6 was used to completely wash through the sample. Basic keratin was eluted from the column with 100 mM tris base plus 2M NaCl at pH 12. Each sample was separately neutralized and dialyzed against DI water using tangential flow dialysis with a LMWCO of 1 KDa, concentrated by rotary evaporation, and freeze dried.
Example 4
Evaluation of Viscosity and Red Blood Cell Aggregation
[0094] As previously described, a sample of alpha-keratose was produced, separated on a DEAE-Sepharose IEx column into acidic and basic fractions, dissolved in PBS, and the pH adjusted to 7.4. These solutions were prepared at 5 weight percent concentration and their RBC aggregation characteristics grossly evaluated with fresh whole human blood by mixing at a 1:1 ratio. Samples were taken after 20 minutes and evaluated by light microscopy. The ion exchange chromatography was highly effective at separating the aggregation phenomenon (data not shown). Basic alpha-keratose was essentially free from interactions with blood cells while the acidic alpha-keratose caused excessive aggregation.
[0095] Samples of acidic and basic alpha keratose, unfractionated alpha+gamma-kerateines, unfractionated alpha+gamma-keratose, and beta-keratose (derived from cuticle) were prepared at approximately 4 w/v % and pH 7.4 in phosphate buffered saline (PBS). Samples were tested for viscosity and red blood cell (RBC) aggregation. These results are shown in
[0000]
TABLE 1
Results of viscosity and RBC aggregation tests on keratin solutions.
Fluid formulations were prepared at approximately 4 w/v % in PBS at
pH 7.4 and tested with human whole blood at a ratio of 1:1.
Viscosity
RBC
Sample Description
(centipoise)
Aggregation*
acidic alpha-keratose (1X AlEx)
5.65
3
acidic alpha-keratose (2X AlEx)
19.7
5
basic alpha-keratose
1.57
2
alpha + gamma-keratose (hydrolyzed)
1.12
1
alpha + gamma-kerateine (unfractionated)
1.59
2
*Degree of aggregation:
1 = none,
5 = high
[0096] The foregoing is illustrative of the present invention, and is not to be construed as limiting thereof. The invention is defined by the following claims, with equivalents of the claims to be included therein. | Methods are provided to produce optimal fractionations of charged keratins that have superior biomedical activity. Also provided are medical implants coated with these keratin preparations. Further provided are methods of treating blood coagulation in a patient in need thereof. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based on, and claims priority to, Japanese Patent Application No. 2013-089452, filed on Apr. 22, 2013, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the invention relate to multilevel conversion circuits that deliver multilevel voltages.
[0004] 2. Description of the Related Art
[0005] FIG. 10 shows an example of a five-level conversion circuit using flying capacitors disclosed in Japanese Unexamined Patent Application Publication No. 2012-182974. This conversion circuit delivers five levels of voltage from a DC power supply composed of series-connected two DC single power supplies DP and DN having three terminals: positive terminal P, a zero terminal M, and a negative terminal N. A series circuit of semiconductor switches S 1 through S 4 , each composed of antiparallel-connected diode and an IGBT, is connected between the positive terminal P and the negative terminal N of the DC power supply. In parallel to a series circuit of the semiconductor switches S 2 and S 3 connected are a series circuit of the semiconductor switches S 5 and S 6 and a capacitor C 1 called a flying capacitor. An AC switch composed of reverse blocking IGBTs S 15 and S 16 that exhibits withstand voltage in a reversed direction is connected between the connection point between the semiconductor switches S 5 and S 6 and the zero terminal M that is a middle potential point of the DC power supply. An AC terminal U is the connection point between the semiconductor switches S 2 and S 3 .
[0006] When the voltage Edcp and Edcn of the respective DC single power supplies DP and DN are each 2E and the voltage Vc 1 across the capacitor C 1 is controlled at E, the circuit having the construction described above delivers five levels of voltage at the AC terminal U. For instance, when the semiconductor switches S 1 , S 2 , S 6 , and S 16 are in the ON state, a voltage 2E is delivered from the AC terminal U; when the semiconductor switches S 1 , S 3 , S 6 , and S 16 are in the ON state, or the semiconductor switches S 2 and S 6 and the AC switch Sac are in the ON state, a voltage E is delivered; when the semiconductor switches S 3 and S 6 and the AC switch Sac are in the ON state, or the semiconductor switches S 2 and S 5 and the AC switch Sac are in the ON state, a voltage zero is delivered; when the semiconductor switches S 2 , S 4 , S 5 , and S 15 are in the ON state, or the semiconductor switches S 3 and S 5 and the AC switch Sac are in the ON state, a voltage −E is delivered; and when the semiconductor switches S 3 , S 4 , S 5 , and S 15 are in the ON state, a voltage −2E is delivered at the AC terminal U.
[0007] In this operation, there are two modes for deliver a voltage E from the AC terminal U in the direction of current toward the load. One of them is through a path 1: the semiconductor switch S 1 →the capacitor C 1 →the semiconductor switch S 3 ; the other is through a path 2: the AC switch Sac→the semiconductor switch S 6 →the capacitor C 1 →the semiconductor switch S 2 . The capacitor C 1 is charged through the path 1 and discharged through the path 2. The average voltage of the capacitor C 1 can be controlled at the value E by detecting the voltage of the capacitor C 1 and appropriately selecting the paths in order for the average value of the voltage to be E. There are similarly two paths for the mode to deliver a voltage −E from the AC terminal U, and the average voltage of the capacitor C 1 can be controlled at the value E.
[0008] FIG. 11 shows an example of conversion circuit that is an extended conversion circuit of seven levels from the conversion circuit of five levels shown in FIG. 10 . The seven level conversion circuit of FIG. 11 has a circuit construction to deliver seven levels of voltage from a DC power supply composed of DC single power supplies DP and DN and having three terminals of a positive terminal P, a zero terminal M, and a negative terminal N. Between the positive terminal P and the negative terminal N connected is a series circuit of semiconductor switches S 1 through S 6 each consisting of a diode and an IGBT antiparallel-connected with each other. In parallel to the series circuit of semiconductor switches S 2 through S 5 connected are a capacitor C 2 and a series circuit of the semiconductor switches S 7 and S 8 . In parallel to the series circuit of semiconductor switches S 3 and S 4 connected is a capacitor C 1 . Between the connection point between the semiconductor switches S 7 and S 8 and the zero terminal M, i.e. the middle potential point of the DC power supply, connected is an AC switch Sac consisting of antiparallel-connected reverse-blocking IGBTs S 15 and S 16 each exhibiting a withstand voltage in the reverse direction. The connection point between the semiconductor switches S 3 and S 4 is the AC terminal U.
[0009] In this circuit construction, when the voltages Edcp and Edcn of the DC single power supplies DP and DN are each 3E, and the voltage Vc 1 across the capacitor C 1 is controlled at E and the voltage Vc 2 across the capacitor C 2 is controlled at 2E, seven levels of voltages are delivered from the AC terminal U. For example, when the semiconductor switches S 1 through S 3 are in the ON state, a voltage 3E is delivered from the AC terminal U; when the semiconductor switches S 1 , S 2 , and S 4 are in the ON state, a voltage 2E is delivered; when the semiconductor switches S 1 , S 5 , and S 4 are in the ON state, a voltage E is delivered; when the AC switch Sac and the semiconductor switches S 7 , S 2 , and S 3 , or the AC switch Sac and the semiconductor switches S 8 , S 5 , and S 4 are in the ON state, a voltage zero is delivered; when the AC switch Sac and the semiconductor switches S 7 , S 2 , and S 4 are in the ON state, a voltage −E is delivered; when the AC switch Sac and the semiconductor switches S 7 , S 5 , and S 4 are in the ON state, a voltage −2E is delivered; and when the semiconductor switches S 4 through S 6 are in the ON state, a voltage −3E is delivered from the AC terminal U. In detail, there are a plurality of control modes other than the ones describe above. They are, however, extended operation of the circuits shown in FIG. 11 and thus detailed description thereon is omitted here.
[0010] In this operation, there are two modes for delivering a voltage E from the AC terminal U. One of them is through a path 1: the semiconductor switch S 1 →the capacitor C 2 →the semiconductor switch S 5 →the semiconductor switch S 4 ; the other is through a path 2: the AC switch Sac→the semiconductor switch S 8 →the capacitor C 2 →the semiconductor switch S 2 →the capacitor C 1 →the semiconductor switch S 4 . The capacitor C 2 is charged through the path 1 and discharged through the path 2. The average voltage of the capacitor C 2 can be controlled at the value 2E by detecting the voltage of the capacitor C 2 and appropriately selecting the paths in order for the average value of the voltage to be 2E. There are similarly two paths for the mode to deliver a voltage −E from the AC terminal U, and the average voltage of the capacitor C 2 can be controlled at the value 2E by appropriately selecting the paths.
[0011] There are two modes for delivering a voltage 2E from the AC terminal U. One of them is through a path 1: the semiconductor switch S 1 →the semiconductor switch S 2 →the capacitor C 1 →the semiconductor switch S 4 ; the other is through a path 2: the semiconductor switch S 1 →the capacitor C 2 →the semiconductor switch S 5 →the capacitor C 1 →the semiconductor switch S 3 . The capacitor C 1 is charged through the path 1 and discharged through the path 2. The average voltage of the capacitor C 1 can be controlled at the value E by detecting the voltage of the capacitor C 1 and appropriately selecting the paths in order for the average value of the voltage to be E. There are similarly two paths for the mode to deliver a voltage −2E from the AC terminal U, and the average voltage of the capacitor C 1 can be controlled at the value E.
[0012] In the seven-level conversion circuit having the construction of FIG. 11 , the semiconductor switches S 7 and S 8 conduct switching with a voltage variation step of two units, i.e. 2E. A large voltage variation in an output waveform generally produces a high micro surge voltage on an AC motor, for example, in the load side corresponding to the voltage variation, causing a problem of dielectric breakdown.
[0013] In order to deal with this problem, the inventor of the present invention has proposed the circuit disclosed in Japanese Unexamined Patent Application Publication No. 2013-146117. FIG. 12 shows the construction of the circuit, in which a DC power supply consisting of series-connected DC single power supplies DP and DN has terminals of a positive terminal P, a zero terminal M, and a negative terminal N in the order of descending electric potential. The terminal M is the base terminal at a potential of zero. Semiconductor switches in the following description are IGBTs each having an antiparallel-connected diode. The other types of semiconductor switchers can be employed, of course. A series circuit of semiconductor switches S 1 through S 6 are connected between the positive terminal P and the negative terminal N. The connection point between the semiconductor switches S 3 and S 4 is an AC terminal U. A series circuit of semiconductor switches S 7 through S 10 and a capacitor C 2 are connected between the connection point between the semiconductor switches S 1 and S 2 and the connection point between the semiconductors switches S 5 and S 6 . An AC switch Sac composed of antiparallel-connected reverse blocking IGBTs S 15 and S 16 is connected between the zero terminal M and the connection point between the semiconductor switches S 8 and S 9 .
[0014] Further, a capacitor C 1 is connected between the higher potential terminal of the semiconductor switch S 3 and the lower potential terminal of the semiconductor switch S 4 , and a capacitor C 3 is connected between the higher potential terminal of the semiconductor switch S 8 and the lower potential terminal of the semiconductor switch S 9 . The capacitors C 1 , C 2 , and C 3 are called flying capacitors. The AC switch Sac can be composed, in place of using the construction of antiparallel connection of the semiconductor switches S 15 and S 16 each exhibiting reverse-blocking ability shown in FIG. 12 , by combination of IGBTs without reverse-blocking ability and diodes as shown in FIGS. 13A-13C . The circuit in FIG. 13A is composed of antiparallel-connected two series circuits each consisting of a diode and an IGBT. The circuits in FIGS. 13B and 13C are composed of two circuits connected in series, each circuit consisting of antiparallel-connected diode and an IGBT.
[0015] The magnitude of the voltage of each of the DC single power supplies DP and DN in the circuit of FIG. 12 is supposed here to be 3E. Similarly to the conventional example of FIG. 11 , the voltages Vc 1 , Vc 2 , and Vc 3 of the capacitors C 1 , C 2 , and C 3 are changed by charging or discharging the capacitors to hold average values of Vc 1 =E, Vc 2 =2E, and Vc 3 =E. When the potential at the zero terminal M is zero, the output voltage Vu at the AC terminal U can be obtained at seven levels of ±3E, ±2E, ±E, and zero by ON/OFF operation of the semiconductor switches. For example, when the semiconductor switches S 1 , S 2 , S 3 , S 9 , S 10 , and S 16 are in an ON state and the other semiconductor switches are in an OFF state, as shown in FIG. 14A , the output voltage at the AC terminal U is +3E, which is the voltage at the terminal P of the DC single power supply DP. When the semiconductor switches S 1 , S 3 , S 5 , S 9 , S 10 , and S 16 are in the ON state and the other semiconductor switches are in the OFF state as shown in FIG. 14B , the output voltage at the AC terminal U is +2E, which is the voltage +3E of the DC single power supply DP minus the voltage +2E of the capacitor voltage Vc 2 plus the voltage +E of the capacitor voltage Vc 1 .
[0016] When the semiconductor switches S 3 , S 5 , S 9 , S 10 , S 15 , and S 16 are in the ON state and the other semiconductor swathes are in the OFF state as shown in FIG. 14C , the output voltage at the AC terminal U is +E, which is the potential zero at the terminal M of the DC power supply plus the voltage +E of the capacitor voltage Vc 1 . When the semiconductor switches S 4 , S 5 , S 9 , S 10 , S 15 , and S 16 are in the ON state and the other semiconductor switches are in the OFF state as shown in FIG. 14D the output voltage at the AC terminal U is zero, which is the potential at the terminal M of the DC power supply. When the semiconductor switches S 3 , S 5 , S 7 , S 9 , S 15 , and S 16 are in the ON state and the other semiconductor switches are in the OFF state as shown in FIG. 14E , the output voltage at the AC terminal U is zero, which is the voltage zero at the terminal M of the DC power supply plus the voltage +1E of the capacitor voltage Vc 3 minus the voltage +2E of the capacitor voltage Vc 2 plus the voltage +1E of the capacitor voltage Vc 1 .
[0017] Electric current flows from the terminal P, M, or N to the AC terminal U as a result of ON/OFF operation of the semiconductor switches in the paths shown in FIGS. 14A through 14E , while charging or discharging the capacitors. There are a multiple of paths for a mode to obtain the same voltage at the AC output terminal similarly to the five-level conversion circuit of FIG. 10 and the seven-level conversion circuit of FIG. 11 . By detecting the voltages of the capacitors and selecting an appropriate path, the voltage control is possible for the capacitors C 1 and C 3 in FIG. 12 at E and the capacitor C 2 at 2E. Other combination of paths can deliver a desired voltage and charge or discharge the capacitors, through details are omitted here.
[0018] The conversion circuit of FIG. 12 provides seven levels of output voltages Vu from the DC power supply having three levels of potential terminals combining the voltages Edcp and Edcn of the DC single power supplies DP and DN and the voltages Vc 1 , Vc 2 , and Vc 3 of the capacitors C 1 , C 2 , and C 3 by means of ON/OFF operation of the semiconductor switches. In order to obtain seven levels of output voltages, the average value of the voltage Vc 1 across the capacitor C 1 is necessarily E, the average value of the voltage Vc 2 across the capacitor C 2 is necessarily 2E, and the average value of the voltage Vc 3 across the capacitor C 3 is necessarily E. In actual operation of the circuit, however, the capacitor voltages Vc 1 , Vc 2 , and Vc 3 change due to the current running in the circuit. In generally employed method for holding the capacitor voltages at the average values, ON/OFF operation of the semiconductor switches S 1 through S 10 and the AC switch Sac is combined to deliver desired voltages and simultaneously control charging and discharging of the capacitors C 1 , C 2 , and C 3 . This control needs a means for detecting the capacitor voltages Vc 1 , Vc 2 , and Vc 3 . Nevertheless, the capacitors have no common potential part. Thus, the voltage detecting circuit needs an insulating function, which increases device costs.
SUMMARY OF THE INVENTION
[0019] Embodiments of the invention address the above-described and other shortcomings in the related art. Some embodiments provide a multilevel conversion circuit capable of controlling the capacitor voltages to desired values at a low cost in which some of the capacitors used in the multilevel conversion circuit is not provided with a voltage detecting circuit.
[0020] A first aspect of the present invention is a multilevel conversion circuit that generates multi-levels of voltage from a DC power supply provided with three terminals, composed of two single power supplies, and having three different voltage levels including zero, and selects and delivers the multi-levels of voltage, the multilevel conversion circuit comprising: first and second switch groups, each switch group comprising series-connected n semiconductor switches, n being an integer of three or larger, having an antiparallel-connected diode; third and fourth switch groups, each switch group comprising series-connected (n−1) semiconductor switches; and an AC switch composed of a combination of reverse-blocking semiconductor switches; wherein a series circuit of the first switch group and the second switch group is connected between a first DC terminal that is one of the three terminals of the DC power supply at the highest potential and a third DC terminal that is one of the three terminals of the DC power supply at the lowest potential, the first switch group being connected to the first DC terminal; a series circuit of the third switch group and the fourth switch group is connected between a negative terminal of a first semiconductor switch composing the first switch group and a positive terminal of an n-th semiconductor switch composing the second switch group, the third switch group being connected to the negative terminal of the first semiconductor switch of the first switch group; the AC switch is connected between a connection point of the third switch group and the fourth switch group and a second DC terminal that is one of the three terminals of the DC power supply at a middle potential; a j-th capacitor, j being an integer from 1 to (n−2), is connected between a positive terminal of an (n−m)-th semiconductor switch composing the first switch group, m being an integer from 0 to (n−3), and a negative terminal of a k-th semiconductor switch composing the second switch group, k being an integer from 1 to (n−2); an (n−1)-th capacitor is connected between a positive side terminal of the third switch group and a negative side terminal of the fourth switch group; an i-th capacitor, i being an integer from n to (2n−3), is connected between a positive terminal of (n−m−1)-th semiconductor switch composing the third switch group and a negative terminal of k-th semiconductor switch composing the fourth switch group; a connection point between the first switch group and the second switch group is an AC terminal; and a linking means connects a terminal of the j-th capacitor and a terminal of the i-th capacitor.
[0021] A second aspect of the invention is the multilevel conversion circuit according to the first aspect of the invention, wherein a j-th diode, which is the linking means, is connected between a positive terminal of the j-th capacitor and a negative terminal of the i-th capacitor; and an (i−1)-th diode, which is the linking means, is connected between a positive terminal of the i-th capacitor and a negative terminal of the j-th capacitor.
[0022] A third aspect of the invention is the multilevel conversion circuit according to the first aspect of the invention, wherein a series circuit of a j-th diode and a j-th resistor, the series circuit being the linking means, is connected between a positive terminal of the j-th capacitor and a negative terminal of the i-th capacitor; and a series circuit of an (i−1)-th diode and an (i−1)-th resistor, the series circuit being the linking means, is connected between a positive terminal of the i-th capacitor and a negative terminal of the j-th capacitor.
[0023] A fourth aspect of the invention is the multilevel conversion circuit according to the first aspect of the invention, wherein a j-th reverse blocking semiconductor switch, which is the linking means, is connected between a positive terminal of the j-th capacitor and a negative terminal of the i-th capacitor; and an (i−1)-th reverse blocking semiconductor switch, which is the linking means, is connected between a positive terminal of the i-th capacitor and a negative terminal of the j-th capacitor.
[0024] A fifth aspect of the invention is the multilevel conversion circuit according to the first aspect of the invention, wherein a j-th impedance element, which is the linking means, is connected between a positive terminal of the j-th capacitor and a positive terminal of the i-th capacitor; and an (i−1)-th impedance element, which is the linking means, is connected between a negative terminal of the i-th capacitor and a negative terminal of the j-th capacitor.
[0025] A sixth aspect of the invention is the multilevel conversion circuit according to any one of the second through fifth aspects of the invention, wherein a Zener diode is connected in parallel with the j-th capacitor, the (n−1)-th capacitor, or the i-th capacitor.
[0026] A multilevel conversion circuit, which is of a flying capacitor type, of some embodiments of the invention comprises a linking means between flying capacitors. This means allows for the omission of voltage detection of some of the capacitors in the conversion circuit, yet controlling the capacitor voltages at desired values. Therefore, the number of capacitor voltage detection circuits is reduced, resulting in reduction of device costs.
BRIEF DESCRIPTION OF DRAWINGS
[0027] FIG. 1 is a circuit diagram of an example of multilevel conversion circuit according to the first embodiment of the present invention;
[0028] FIG. 2A illustrates an operation mode of the multilevel conversion circuit according to the first embodiment of the present invention;
[0029] FIG. 2B illustrates another operation mode of the multilevel conversion circuit according to the first embodiment of the present invention;
[0030] FIG. 3 is a circuit diagram of an example of multilevel conversion circuit according to the second embodiment of the present invention;
[0031] FIG. 4 is a circuit diagram of an example of multilevel conversion circuit according to the third embodiment of the present invention;
[0032] FIG. 5 is a circuit diagram of an example of multilevel conversion circuit according to the fourth embodiment of the present invention;
[0033] FIG. 6 is a circuit diagram of an example of multilevel conversion circuit according to the fifth embodiment of the present invention;
[0034] FIG. 7 is a circuit diagram of an example of multilevel conversion circuit according to the sixth embodiment of the present invention;
[0035] FIG. 8 illustrates the operation of the multilevel conversion circuit according to the sixth embodiment of the present invention;
[0036] FIG. 9 is a circuit diagram of an example of multilevel conversion circuit according to the seventh embodiment of the present invention;
[0037] FIG. 10 shows an example of conventional five level conversion circuit;
[0038] FIG. 11 shows an example of conventional seven level conversion circuit;
[0039] FIG. 12 shows an example of conventional seven level conversion circuit of an improved type;
[0040] FIGS. 13A-13C show examples of AC switching circuits;
[0041] FIG. 14A illustrates an operation mode (a) of the improved seven level conversion circuit;
[0042] FIG. 14B illustrates an operation mode (b) of the improved seven level conversion circuit;
[0043] FIG. 14C illustrates an operation mode (c) of the improved seven level conversion circuit;
[0044] FIG. 14D illustrates an operation mode (d) of the improved seven level conversion circuit; and
[0045] FIG. 14E illustrates an operation mode (e) of the improved seven level conversion circuit.
DETAILED DESCRIPTION
[0046] A multilevel conversion circuit of embodiments of the invention generates multi-levels of voltage from a DC power supply having three voltage levels, the multilevel conversion circuit comprising: a series circuit of first and second switch groups connected between a positive terminal and a negative terminal of the power supply, each switch group comprising series-connected n semiconductor switches, n being an integer of three or larger; a series circuit of third and fourth switch groups connected between a negative terminal of a first semiconductor switch composing the first switch group and a positive terminal of an n-th semiconductor switch composing the second switch group, the third group being connected to a negative terminal of the first semiconductor switch of the first switch group, each of the third and fourth switch groups comprising series-connected (n−1) semiconductor switches; and an AC switch composed of a combination of reverse-blocking semiconductor switches connected between a connection point of the third switch group and the fourth switch group and a middle terminal of the DC power supply; wherein a j-th capacitor, j being an integer from 1 to (n−2), is connected between a positive terminal of an (n−m)-th semiconductor switch composing the first switch group, m being an integer from 0 to (n−3), and a negative terminal of a k-th semiconductor switch composing the second switch group, k being an integer from 1 to (n−2); an (n−1)-th capacitor is connected between a positive side terminal of the third switch group and a negative side terminal of the fourth switch group; an i-th capacitor, i being an integer from n to (2n−3), is connected between a positive terminal of (n−m−1)-th semiconductor switch composing the third switch group and a negative terminal of k-th semiconductor switch composing the fourth switch group; a connection point between the first switch group and the second switch group is an AC terminal; and at least one linking means connects a terminal of the j-th capacitor and a terminal of the i-th capacitor.
Embodiment Example 1
[0047] FIG. 1 is a circuit diagram of an example of multilevel conversion circuit according to a first embodiment of the present invention. This is a seven-level conversion circuit that is an example of the number n in claims of three. A DC power supply consisting of series-connected DC single power supplies DP and DN has terminals of a positive terminal P, a zero terminal M, and a negative terminal N in the order of descending electric potential values. The terminal M is the base terminal at a potential of zero. Semiconductor switches in the following description are IGBTs each having an antiparallel-connected diode. The other types of semiconductor switchers can be employed, of course. A series circuit of semiconductor switches S 1 through S 6 are connected between the positive terminal P and the negative terminal N. The connection point between the semiconductor switches S 3 and S 4 is an AC terminal U. A series circuit of semiconductor switches S 7 through S 10 and a capacitor C 2 are connected in parallel between the connection point between the semiconductor switches S 1 and S 2 and the connection point between the semiconductor switches S 5 and S 6 . An AC switch Sac composed of semiconductor switches of antiparallel-connected reverse blocking IGBTs S 15 and S 16 is connected between the zero terminal M and the connection point between the semiconductor switches S 8 and S 9 .
[0048] Further, a capacitor C 1 is connected between the higher potential terminal of the semiconductor switch S 3 and the lower potential terminal of the semiconductor switch S 4 , and a capacitor C 3 is connected between the higher potential terminal of the semiconductor switch S 8 and the lower potential terminal of the semiconductor switch S 9 . A diode D 1 that is a linking means is connected between the higher potential terminal of the capacitor C 1 and the lower potential terminal of the capacitor C 3 , and a diode D 2 that is a linking means is connected between the higher potential terminal of the capacitor C 3 and the lower potential terminal of the capacitor C 1 .
[0049] In the case the voltages of the DC single power supplies DP and DN are each 3E, the voltage across the capacitor C 1 is E, the voltage across the capacitor C 2 is 2E, and the voltage across the capacitor C 3 is E, a voltage +3E is delivered at the AC terminal U when the semiconductor switches S 1 , S 2 , S 3 , S 9 , S 10 , and S 16 are in an ON state and the other semiconductor switches are in an OFF state. If the relationship between the voltages Vc 1 , Vc 2 , and Vc 3 of the respective capacitors C 1 , C 2 , and C 3 is Vc 2 >Vc 1 +Vc 3 , the capacitor C 2 is discharged and the capacitors C 1 and C 2 are charged so that the relationship Vc 2 =Vc 1 +Vc 3 is reached. The current Ic between the capacitors C 1 , C 2 , and C 3 flows, as shown by the dotted line in FIG. 2A , through the path of the capacitor C 2 →the semiconductor switch S 2 →the capacitor C 1 →the diode D 2 →the capacitor C 3 →the semiconductor switch S 10 →the capacitor C 2 . The sum of the voltage Vc 1 of the capacitor C 1 and the voltage Vc 3 of the capacitor C 3 is clamped at the voltage Vc 2 of the capacitor C 2 in the mode shown in FIG. 2A and also in other modes in which at least the semiconductor switches S 2 and S 10 are in the ON state and a path is formed to charge the capacitor C 1 and the capacitor C 3 from the capacitor C 2 .
[0050] A voltage zero is delivered at the AC terminal U when the semiconductor switches S 3 , S 5 , S 7 , S 9 , S 15 , and S 16 are in an ON state and the other semiconductor switches are in an OFF state. Here, if the relationship between the voltages Vc 1 , Vc 2 , and Vc 3 of the respective capacitors C 1 , C 2 , and C 3 is Vc 2 >Vc 1 +Vc 3 , the capacitor C 2 is discharged and the capacitors C 1 and C 2 are charged so that the relationship Vc 2 =Vc 1 +Vc 3 is reached. The current Ic between the capacitors C 1 , C 2 , and C 3 flows, as shown by the dotted line in FIG. 2B , through the path of the capacitor C 2 →the semiconductor switch S 7 →the capacitor C 3 →the diode D 1 →the capacitor C 1 →the semiconductor switch S 5 →the capacitor C 2 . The sum of the voltage Vc 1 of the capacitor C 1 and the voltage Vc 3 of the capacitor C 3 is clamped at the voltage Vc 2 of the capacitor C 2 . The sum of the voltage Vc 1 of the capacitor C 1 and the voltage Vc 3 of the capacitor C 3 is clamped at the voltage Vc 2 of the capacitor C 2 in the mode shown in FIG. 2B and also in other modes in which at least the semiconductor switches S 5 and S 7 are in the ON state and a path is formed to charge the capacitor C 1 and the capacitor C 3 from the capacitor C 2 . Here, when appropriate path is selected, similarly to the conventional technology, to control the voltage across the capacitor C 1 at E and the voltage across the capacitor C 2 at 2E, the voltage across the capacitor C 3 becomes at E. Thus, the voltage across the capacitor C 3 does not need to be detected, eliminating a detecting circuit for the voltage and achieving cost reduction.
Embodiment Example 2
[0051] FIG. 3 shows a multilevel conversion circuit according to a second embodiment of the invention. This circuit uses a resistance for an impedance element. Linking means in this Embodiment Example 2 are a series circuit of a diode D 1 and a resistor R 1 and a series circuit of diode D 2 and a resistor R 2 , in place of the diodes in Embodiment Example 1. Operation of the semiconductor switches and relationship between the capacitor voltages Vc 1 , Vc 2 , and Vc 3 are the same as those in Embodiment Example 1. Voltage detection of the capacitor C 3 is also not necessary in this Embodiment Example 2. The resistors used in the linking means enables a charging time adjusted. When an inductor is used instead of the resistor, inrush current is suppressed.
Embodiment Example 3
[0052] FIG. 4 shows a multilevel conversion circuit according to Embodiment Example 3 of the present invention. This circuit is a modified one from the circuit of Embodiment example 1 into a circuit in which all semiconductor switches and diodes have an equal withstand voltage. The number n in this example is again three. The semiconductor switch S 1 and the semiconductor switch S 6 in FIG. 1 are replaced by series-connected four semiconductor switches S 1 a through S 1 d and series-connected four semiconductor switches S 6 a through S 6 d, respectively. The diode D 1 and the diode D 2 , which are linking means in FIG. 1 , are changed to series-connected two diodes D 1 a and D 1 b and series-connected two diodes D 2 a and D 2 b, respectively. Operation of the semiconductor switches and relationship between the capacitor voltages Vc 1 , Vc 2 , and Vc 3 are the same as those in Embodiment Example 1. Voltage detection of the capacitor C 3 is also not necessary in this Embodiment Example 3. Because all the semiconductor switches and diodes have an equal withstand voltage, this conversion circuit has advantages of simplified device construction and easy parts management.
Embodiment Example 4
[0053] FIG. 5 shows a multilevel conversion circuit according to Embodiment Example 4 of the present invention. In this circuit of Embodiment Example 4, the linking means of the diodes D 1 and D 2 in Embodiment Example 1 is replaced by a linking means of semiconductor switches Sr 1 and Sr 2 with reverse-blocking ability. While each of the semiconductor switches Sr 1 and Sr 2 with reverse-blocking ability of the circuit of FIG. 5 consists of a diodes and an IGBT without reverse-blocking ability, a reverse blocking IGBT can eliminates the series-connected diode in the circuit of FIG. 5 . If the semiconductor switches Sr 1 and Sr 2 are made constantly in an ON state, the circuit of this embodiment provides the same effect as the circuit of Embodiment Example 1. When it is impossible to maintain the relationship of the voltages across the capacitors C 1 and C 3 at the value E and the voltage across the capacitor C 2 at the value 2E in the circuit of Embodiment Example 1, the semiconductor switch Sr 1 or Sr 2 is ON/OFF operated to control the capacitor voltages to desired values. Operation of the conversion circuit under the condition of the ON states of the semiconductor switches Sr 1 and Sr 2 are the same as those in Embodiment Example 1. Voltage detection of the capacitor C 3 is also not necessary in this Embodiment Example 4. When a current path is appropriately selected, as in the conventional technology, to control the voltage across the capacitor C 1 at E and the voltage across the capacitor C 2 at 2E, the voltage across the capacitor C 3 becomes at the desired value of E without a voltage detection circuit. When resistances or inductances are added to the reverse-blocking semiconductor switches Sr 1 and Sr 2 , the effects same as those in Embodiment Example 2 are obtained.
Embodiment Example 5
[0054] FIG. 6 shows a multilevel conversion circuit according to Embodiment Example 5 of the present invention. In this circuit of Embodiment Example 5, a Zener diode ZD 1 is connected in parallel to the capacitor C 3 in the circuit of Embodiment Example 1. When a current path is appropriately selected, as in the conventional technology, to control the voltage across the capacitor C 1 at E and the voltage across the capacitor C 2 at 2E, the voltage across the capacitor C 3 becomes at the desired value of E without a voltage detection circuit. In the circuit of Embodiment Example 1 as shown in FIGS. 2A and 2B , the capacitors C 1 and C 3 are always charged. As a result, the capacitors may suffer over-voltage, which requires discharging. To cope with this issue, the Zener diode is provided in parallel to the capacitors and the capacitor voltages are clamped at the Zener voltage, thereby allowing discharging as well as charging. Whereas the Zener diode is connected in parallel to the capacitor C 3 in the embodiment of FIG. 6 , the Zener diode can be connected in parallel to one, two, or three of the capacitors C 1 , C 2 and C 3 .
Embodiment Example 6
[0055] FIG. 7 shows a multilevel conversion circuit according to Embodiment Example 6 of the present invention. This circuit of Embodiment Example 6 has a construction of the conventional example of FIG. 12 with additional resistors R 1 connected between the positive potential terminal of the capacitor C 1 and the positive potential terminal of the capacitor C 3 and R 2 connected between the negative potential terminal of the capacitor C 1 and the negative potential terminal of the capacitor C 3 . This construction allows charging or discharging the capacitors C 1 and C 3 to equalize the voltage Vc 1 of the capacitor C 1 and the voltage Vc 3 of the capacitor C 3 . If the relationship between the capacitor voltage Vc 1 and the capacitor voltage Vc 3 is Vc 1 >Vc 3 , a current flows, as shown with the dotted line in FIG. 8 , in the path of the capacitor C 1 →resistor R 1 →capacitor C 3 →resistor R 2 →capacitor C 1 , and the voltages becomes Vc 1 =Vc 3 . On the contrary, if the relationship between the capacitor voltage Vc 1 and the capacitor voltage Vc 3 is Vc 1 <Vc 3 , a current flows in the path of the capacitor C 3 →resistor R 1 →capacitor C 1 →resistor R 2 →capacitor C 3 , and the voltages becomes Vc 1 =Vc 3 . When a current path is appropriately selected, as in the conventional technology, to control the voltage across the capacitor C 1 at E and the voltage across the capacitor C 2 at 2E, the voltage across the capacitor C 3 becomes at the desired value of E without a voltage detection circuit. In this Embodiment Example 6, the capacitor voltages Vc 1 and Vc 3 can be balanced through the resistors even though all the semiconductor switches are in an OFF state. This construction can be applied to a circuit with capacitors that are designed to be controlled at an equal voltage.
Embodiment Example 7
[0056] FIG. 9 shows a multilevel conversion circuit according to Embodiment Example 7 of the present invention. This circuit of Embodiment Example 7 is a nine-level conversion circuit with the number n in claims of four. For this nine level conversion circuit of a flying capacitor type, a DC power supply consisting of series-connected DC single power supplies DP and DN has terminals of a positive terminal P, a zero terminal M, and a negative terminal N in the order of descending electric potential values. The terminal M is the base terminal at a potential of zero. Semiconductor switches in the following description are IGBTs each having an antiparallel-connected diode. Other types of semiconductor switchers can be employed, of course. A series circuit of semiconductor switches S 1 through S 8 are connected between the positive terminal P and the negative terminal N. The connection point between the semiconductor switches S 4 and S 5 is an AC terminal U. A series circuit of semiconductor switches S 9 through S 14 and a capacitor C 3 are connected in parallel between the connection point between the semiconductor switches S 1 and S 2 and the connection point between the semiconductors switches S 7 and S 8 . An AC switch Sac composed of antiparallel-connected reverse blocking IGBTs S 15 and S 16 is connected between the zero terminal M and the connection point between the semiconductor switches S 11 and S 12 .
[0057] Further connected are: a capacitor C 2 between the higher potential terminal of the semiconductor switch S 3 and the lower potential terminal of the semiconductor switch S 6 , a capacitor C 1 between the higher potential terminal of the semiconductor switch S 4 and the lower potential terminal of the semiconductor switch S 5 , a capacitor C 4 between the higher potential terminal of the semiconductor switch S 10 and the lower potential terminal of the semiconductor switch S 13 , and a capacitor C 5 between the higher potential terminal of the semiconductor switch S 11 and the lower potential terminal of the semiconductor switch S 12 . These capacitors C 1 through C 5 are called flying capacitors. The AC switch Sac can be composed, in place of using the construction of antiparallel connection of the semiconductor switches S 15 and S 16 each exhibiting reverse-blocking ability shown in FIG. 9 , by combination of IGBTs without reverse-blocking ability and diodes as shown in FIG. 13 . Circuit (a) in FIG. 13 is composed of antiparallel-connected two series circuits each consisting of a diode and an IGBT. The circuits (b) and (c) in FIG. 13 are composed of two circuits connected in series, each circuit consisting of antiparallel-connected diode and an IGBT.
[0058] Moreover, linking means are provided, which are: a liking means of diode D 1 connected between the higher potential terminal of the capacitor C 1 and the lower potential terminal of the capacitor C 4 , a linking means of diode D 2 connected between the higher potential terminal of the capacitor C 2 and the lower potential terminal of the capacitor C 5 , a linking means of diode D 3 connected between the higher potential terminal of the capacitor C 4 and the lower potential terminal of the capacitor C 1 , and a linking means of diode C 4 connected between the higher potential terminal of the capacitor C 5 and the lower potential terminal of the capacitor C 2 .
[0059] In the circuit construction of FIG. 9 , the magnitudes of each of the voltages of the single power supplies DP and DN is supposed to be 4E. Average values of the voltages Vc 1 through Vc 5 of the capacitors C 1 through C 5 are held at Vc 1 =E, Vc 2 =2E, Vc 3 =3E, Vc 4 =2E, and Vc 5 =E by charging or discharging the capacitors C 1 through C 5 . The potential at the zero terminal M is supposed to be zero. The output voltage Vu at the AC terminal U can be nine levels of output voltages of ±4E, ±3E, ±2E, ±1E, and 0 by means of ON/OFF operation of the semiconductor switches.
[0060] The linking means of diodes D 1 through D 4 are so connected that the sum of the voltage Vc 1 of the capacitor C 1 and the voltage Vc 4 of the capacitor C 4 is equal to the voltage Vc 3 of the capacitor C 3 , and that the sum of the voltage Vc 5 of the capacitor C 5 and the voltage Vc 2 of the capacitor C 2 is equal to the voltage Vc 3 of the capacitor C 3 . Because the detailed operation is similar to the operation in Embodiment Example 1, descriptions thereon are omitted here. The sum of the voltage Vc 1 of the capacitor C 1 and the voltage Vc 4 of the capacitor C 4 is clamped to the voltage Vc 3 of the capacitor C 3 , and the sum of the voltage Vc 5 of the capacitor C 5 and the voltage Vc 2 of the capacitor C 2 is clamped to the voltage Vc 3 of the capacitor C 3 . In this construction, similarly to the conventional technology, the voltages across the capacitors C 1 , C 2 , and C 3 are detected and charging and discharging paths of the capacitors are appropriately selected to control the voltage of the capacitor C 1 at the value E, the voltage of the capacitor C 2 at the value 2E, and the voltage of the capacitor C 3 at the value 3E. As a result, the voltage of the capacitor C 4 becomes at the value 2E without detecting the voltage of the capacitor C 4 , and the voltage of the capacitor C 5 becomes at the value E without detecting the voltage of the capacitor C 5 . Thus, voltage detecting circuits are unnecessary for the capacitors C 4 and C 5 , reducing the device costs. This nine-level conversion circuit can also employ the circuits of Embodiment Examples 2 through 6.
[0061] Whereas the description thus far is given concerning the seven-level conversion circuit and the nine-level conversion circuit, the present invention can be applied to multilevel conversion circuits of 11-levels or more. Whereas the description is given for examples using semiconductor switches of IGBTs, other types of semiconductor switches including MOSFETs and GTOs can also be used in the invented circuits.
[0062] The present invention can be applied to high voltage motor driving equipment and power conversion equipment for power system interconnection that deliver a multilevel voltage from a DC power supply consisting of series-connected two DC single power supplies having three terminals. | In aspects of the invention, a multilevel conversion circuit can include a configuration for linking capacitors, including diodes, reverse-blocking semiconductor switches, and resistors, and a circuit for clamping the capacitor voltage at a specified voltage. Such a configuration can serve to reduce the number of capacitors that need detection of the voltages thereof and appropriate changing-over operation of semiconductor switches to control the capacitor voltage to a desired value. By way of aspects of the invention, desired voltages can be provided to the capacitors. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a method for making a textile web with a base web and at least one tubular knitting region extending transversely to a knitting direction on a straight and circular knitter with at least two opposite needle beds.
[0002] Such tubular knitting regions, until now, with one-bed or two-bed, area textile webs are formed in a manner, such that on both of the opposite needle beds, independent web paths are formed and these are consolidated again to one web path. With this method according to the state of the art, it is not possible to form a tubular knitting section with double-surface textile webs for each knitting plane.
[0003] Tubular knitting regions are provided in clothing articles, in particular, in the form of bands on the waistline and on leg or arm cuffs. These bands are made, such that on the leg or the waistband, knitted, U-shaped folded textile webs are sewed on. Another possibility is that one the arms or legs or in the waistband area, the textile web is formed to the doubled-band height and then the web is folded over to the band height, and the free foldover edges are sewed to the web. Both techniques used up to this point, then, require a sewing operation after making the textile web.
[0004] An object of the present invention is to make a textile web with tubular knitting sections without requiring a sewing operation.
[0005] This object is solved with a method of the above-described type, in which the tubular region(s) each are made on a needle bed, whereby from a starting knitting row, a part of the needles each hold knitting of the base web without knitting, and with the other needles, knitting rows for making the tubular region corresponding to the desired size are formed, before, in an ending knitting row of the tubular region, knitting is again formed with the needles holding the knitting of the base web, and whereby the free end of the tubular region is connected with the base web.
[0006] With this method, it is possible for the first time to make textile webs on a straight and circular knitter, in particular, articles of clothing with tubular sections at each desired region of the textile web, without having to perform a sewing operation. Thus, for example, pantyhose, including the elastic cuffs on the legs and the waistband, can be made completely on the machine. In this manner, it is possible to knit the band of the cuffs with all of the needles of a needle bed, whereby the desired high elasticity of the cuffs can be achieved.
[0007] The at least one tubular knitting region, therefore, can be formed in the same or different binding, with the same or different knitting threads, with the same or different strength, and in the same or different thickness as the base web. It is also possible to knit elastic threads, floating thread, or the like together with one another in the tubular region.
[0008] The textile web of the present invention has a base web and at least one tubular knitting region extending transversely to the knitting direction.
[0009] The base web, therefore, can be an areal, one bed web, an areal, double-bed, a spatial one-bed, or a spatial, two-bed web. The textile web can have at least one tubular knitting region on one or both web sides.
[0010] Thus, it is possible to provide a tubular knitting region at the beginning and/or on the end and/or at any position between the beginning or end of the base web. Therefore, then, not only waistbands or arm and leg cuffs can be made, but also tubular sections as parts of the fabric pattern of an article of clothing. If the textile web operates as a technical web, then, for example, tubular regions can be formed as attachment elements of the web to a tubular frame of the like.
[0011] In this manner, at least one tubular knitting region can be made in any knitting binding, with any strength, in any knitting volume, and with any knitting thread.
[0012] In addition, the at least one tubular knitting region can extend over the entire width, or the entire length, or only over a part of the width or length, of the base web.
[0013] Further advantages are provided if at least one tubular knitting region varies over its length in size. In this regard, in particular, style-related or also technical affects can be achieved.
[0014] In addition, it is also possible that the at least one tubular region is not closed sectionally, that is, that it is not connected with its free end completely with the base web. This is particularly an advantage with technical webs, since then the possibility of laterally inserting objects into the tubular region is provided.
[0015] A classical textile web piece according to the present invention is certainly an article of clothing, in which the at least one tubular region forms a band of the web. The invention, however, is not limited to this feature. If the tubular region is a band, then the foldover edge can be formed by means of a knitting row in a corresponding binding, such that both band sides can be folded flatly and the visible edge is optically appealing.
[0016] The invention also relates to a textile web, which is made on a straight and circular knitter with more than two needle beds, which is characterized in that it has at last one double-surface, tubular region. By providing further needle beds, this is possible technically without further devices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIGS. 1 a - 1 c shows a plan view and sectional views of an areal textile web with multiple tubular regions;
[0018] [0018]FIGS. 2 a - 2 c show a plan view and sectional views of a spatial web with multiple tubular sections;
[0019] [0019]FIGS. 3 a - 3 c show principle illustrations of the making of tubular knitting regions at different points of the base web;
[0020] [0020]FIG. 4 shows a run of thread illustration of making a tubular knitting section on a base web;
[0021] [0021]FIG. 5 shows a plan view of woven pants with tubular cuffs; and
[0022] [0022]FIG. 6 shows a plan view of a chair back rest with tubular attachment regions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] [0023]FIGS. 1 a shows in a schematic representation a textile web 1 with an areal base web 10 , 10 ′, whereby the base web 10 , 10 ′ can be single-faced (FIG. 1 b ) or double-faced (FIG. 1 c ). On the base web 10 , three tubular regions 11 , 12 , 13 are arranged.
[0024] As the sectional illustrations of FIGS. 1 b and 1 c show, the regions 11 , 13 form cuffs on lower or upper ends of the textile web 1 , while the tubular region 12 is arranged in a center region of the web 1 . With the double-faced web 10 ′ from FIG. 1 c, also tubular regions 11 ′, 12 ′, 13 ′ are arranged on the second base web side in a mirror image to the regions 11 , 12 , 13 .
[0025] In FIG. 2, one example of a tubular web 2 with tubular regions 21 , 22 , 23 is shown. The tubular regions 21 , 22 , 23 are arranged on a base web 20 , which has a front side 20 and a back side 20 ′ (FIG. 2 b ). As the sectional illustrations in FIGS. 2 b and 2 c show, the tubular sections 21 , 22 , 23 extend seamlessly over the entire extent of the web 2 . The regions 21 , 23 are again cuffs at the beginning and on the end of the web 2 . The region 22 is a tubular section in the center region of the web 2 . By the tube-shaped structure of the web 2 , the tubular regions 21 , 22 , 23 are formed on the front side 20 of the base web on the front needle bed and the tubular regions 21 ′, 22 ′, 23 ′ are formed on the back side 20 ′ of the base web on the rear needle bed.
[0026] With the webs 1 and 2 of FIGS. 1 and 2, the tubular regions 11 , 12 , 13 , 11 ′, 12 , 13 ′, and 21 , 22 , 23 run parallel to the base web side. This must not always be the case, however. They could also run at any angle to the base web side or to the knitting direction.
[0027] [0027]FIG. 3 a shows schematically the making of the tubular regions 11 , 21 at the beginning of the web 1 , 2 from FIGS. 1 and 2. The starting knitting row 15 of the tubular region 11 , 21 is simultaneously the starting knitting row for the entire textile web piece 1 , 2 . The tubular web 11 , 21 ends with the ending knitting row 16 . From the knitting row 17 , then, the base web 10 , 20 begins. The line 30 marks the interface between the band region 11 , 21 and the base web 10 , 20 .
[0028] [0028]FIG. 3 b shows the making of a tubular region 12 , 22 at any point between the beginning and the end of the base web 10 , 20 . The base web 10 , 20 is therefore knitted from under until reaching the line 30 . Next, the tubular region 12 , 22 is prepared beginning with the starting knitting row 15 to the ending knitting row 16 . The ending knitting row 16 therefore serves as the connection of the tubular region 12 , 122 to the base web 10 , 20 , which is continued from the row 17 , then, again areally.
[0029] [0029]FIG. 3 c schematically describes the making of an upper terminating band on the base web 10 , 20 . The last row of the base web 10 , 20 is designated with reference numeral 18 . From knitting row 15 , the formation of the band 13 , 23 begins, which again ends with the knitting row 16 , in which the connection to the base web 10 , 20 takes place.
[0030] [0030]FIG. 4 shows by way of example the knitting course for making a tubular knitting sections. The knitting course relates to a tube-shaped, spatial web, such as the web 2 in FIG. 2. The base web is a flat web, which is formed with all needles of the corresponding section of the front and rear needle beds. Also, the tubular knitting section 22 , 23 is a flat web in the illustrated example.
[0031] [0031]FIG. 4 a shows the last knitting rows 18 , 18 ′ of the tube-shaped base web 20 . The needles A to O of the front needle bed V form knitting of the last knitting row 18 on the front knitting bed and the needles a through o form knitting of the last knitting row 18 ′ on the rear needle bed.
[0032] [0032]FIG. 4 b shows the first knitting rows 15 , 15 ′ of the tubular knitting region 21 , 22 , 23 (FIG. 2). The designated knitting is therefore knitting which serves only for making the base web 20 , not, however, for making the tubular regions 21 , 22 , 23 . In the knitting rows 15 , 15 ′of the front and rear needle beds V, H, no knitting is formed with the needles B, F, J, N, and d, h, l. All other needles, however, form knitting, which can be seen in particular in FIG. 4 c. The knitting process shown in FIG. 4 c is repeated until the desired diameter of the tubular region is reached. Thereafter, knitting is formed with all needles in the terminating knitting rows 16 , 16 ′ shown in FIG. 4 d, whereby the free end of the tubular region is connected with the base web 20 . The connection takes place by means of the knitting B, F, J, N on the front needle bed V and by means of the knitting b, h, l on the rear needle bed H. It is logical to uniformly distribute this connection knitting over the length of the tube-shaped knitting region; however, this need not be the case unconditionally. If a large area of the connecting knitting remains omitted, then the tubular knitting region 21 , 22 , 3 is open at this position, which, for example, can be desired with technical webs for insertion of attachment elements therethrough.
[0033] [0033]FIGS. 5 and 6 show two possible knitting pieces, which can be formed as the knitting pieces of the present invention. In FIG. 5, knitted pants are shown, which are provided on the lower leg cuff and in the waistband, respectively, with a band 21 , 21 ′ and 23 , 23 ′. The pants 3 are formed from a tube-shaped base web 20 , 20 ′ therebetween.
[0034] [0034]FIG. 6 shows the example of a knitted back rest 4 , which is pulled over a frame 25 . For receiving the frame bars, the web piece 4 has tubular regions 11 , 13 . The web piece 4 therefore is knitted beginning from the tubular side 11 to the tubular side 13 .
[0035] 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 constructions differing from the types described above.
[0036] While the invention has been illustrated and described herein as a method for making a textile web with a tubular knitting region, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
[0037] 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 method for making a textile web with a base web and at least one tubular knitting region ( 21, 21′, 23, 23′ ) extending transversely to a knitting direction on a straight and circular knitter with at least two opposite needle beds includes making the tubular region(s) ( 21, 21′, 23, 23′ ) on a needle bed, whereby from a starting knitting row ( 15, 15′ ), a part of the needles (B, F, J, N, d, n, 1 ) respectively hold the knitting of the base web without knitting and with the other needles, knitting rows for making the tubular region according to the desired length are formed, before knitting is formed again in an ending knitting row ( 16, 16′ ) of the tubular region with the needles (B, F, J, N, d, h, 1 ) holding the knitting of the base web. The free end of the tubular region is connected with the base web. | 3 |
TECHNICAL FIELD
The invention relates to a control circuit through which electrical means can be controlled and the operating states thereof can be monitored.
BACKGROUND OF THE INVENTION
Such a control circuit is used, for example, for controlling and monitoring a central locking means of a motor vehicle. Such a control means can be used quite generally for controlling and monitoring a so-called automatic state apparatus which is capable of producing a predetermined number of states, changes from one state to another state on the basis of actual states and input variables and produces output signals in doing so.
DE 42 21 142 A1 discloses a central locking system for a motor vehicle, comprising a transmitter incorporated in a door key and a receiver accommodated in the motor vehicle. By means of the transmitter, a code is transmitted that is decoded by the receiver and causes actuation of the central locking system when the correct code has been transmitted. Transmitter and receiver thus constitute a remote control means. For permitting the latter to operate selectively either with radio frequencies or with light frequencies, there are provided on the transmitter side both an HF oscillator and a light wave oscillator whose HF carrier and light wave, respectively, can each be modulated with the code word on the transmitter side, and on the receiver side there are provided both a HF detector and a light wave detector whose output signals are fed to a common decoder means.
U.S. Pat. No. 417 discloses a remotely controllable central locking system for a motor vehicle, with the receiver thereof, which is arranged within the motor vehicle, being periodically turned on and off in order to reduce the overall power consumption. For making sure that the central locking system is definitely responsive in case of transmission of a code signal from a transmitter, the code pulse sequence on the transmitter side is preceded by a leader pulse having a duration that is longer than the time distance between two successive on-state intervals of the receiver. In this manner, the receiver is safely activated by the leader pulse, so as to be able to receive and process the code pulse sequence thereafter. To this end, the receiver is provided with a clock pulse generator delivering clock pulses corresponding to the on-state intervals of the receiver to a first input of an AND circuit. A second input of the AND circuit is fed with pulses that are received by the transmitter and shaped. If a pulse from the transmitter is received by the timer during a clock pulse, the then created output signal of the AND circuit triggers a monostable multivibrator, the output signal of which turns on a power supply of the receiver for a predetermined period of time that is at least as long as the code pulse sequence transmitted by the transmitter subsequently to a leader pulse. When no pulse from the transmitter has been received during a clock pulse, the power supply of the receiver is turned on only for the particular duration of the clock pulse.
EP 0 457 964 A1 reveals a remote operating system for controlling additional apparatus for vehicles, whose receiver arranged in the vehicle is periodically turned on and off in order to reduce the average power consumption of the receiver. During a transmission operation, the transmitter is turned on each time for a period of time of such duration that at least one on-state interval of the receiver is present therein so that the receiver can definitely be responsive to a transmission operation.
DE 43 02 232 A1 discloses an apparatus for operating a microprocessor, by means of which the microprocessor can be operated in an active and in an inactive operating state so as to reduce the load acting on the battery supplying current to the microprocessor. In the inactive state, the microprocessor may be brought to the active state either by a wake-up signal of a watchdog provided in the microprocessor or by an external wake-up signal issued periodically by an external oscillator. The external oscillator is composed with two CMOS inverters.
A conventional control circuit of the type indicated at the outset comprises a control means, which may be a microcontroller, and a main oscillator delivering a clock signal for operation of the control means. In addition thereto, such a control circuit may contain a state monitoring means through which the states of predetermined electrical means, such as electrical switching contacts, sensors and/or detectors, can be monitored and state signals representing the respective states can be delivered to the control means.
Due to the high clock frequencies that may be employed by digital control means of modem nature, in particular in the form of the already mentioned microcontrollers, quartz oscillators are used having oscillation frequencies in the MHz range. Both such control means as well as such oscillators consume relatively much power, which may turn out problematic for example in such cases in which the means controlled by the control circuit is not required for long periods of time. If such a control circuit is used, for example, for controlling a central locking system of a motor vehicle, it may happen that the control circuit is not being used for a long period of time, for example when the motor vehicle is not in use for days, weeks or even months. In order to avoid that the electrical source of energy, in the example mentioned a motor vehicle battery, is subjected to undesirable loads, it is known to switch the control circuit, when its control function is not required for a longer period of time, to a current-saving waiting or standby mode of operation in which control circuit components with relatively high power consumption, such as the control means and the oscillator, are turned off.
In the standby mode, only such parts of the control circuit are kept in the on-state mode which serve for state control of electrical means, such as sensors, detectors and switch contacts. In this manner, it is possible to determine when a need for control by the control unit arises again, so as to be able to reset the control circuit to full operation thereof in case of such determination. Control circuit parts that are deactivated during standby operation are thus put into operation again.
For reasons of functional safety, the control circuit is also reset to full operation for a short wake-up period each when no control necessity is present. Such temporary resetting to full operation usually takes place periodically. For example, after standby periods of a duration of several seconds each, resetting to full operation takes place for a wake-up period of several milliseconds each. In this example, the control circuit is in full operation only in the range of some few percent of the total time, and the remaining time in the standby mode. The average power consumption by the control circuit parts with noticeable power consumption is correspondingly reduced to some few percent of the power consumption that would arise if the control circuit were kept in full operation at all times.
For controlling the control circuit parts held in the on-state during the standby mode as well as for controlling the alternating standby periods and periods of full operation, an oscillator is required for making available clock signals necessary therefor, and the frequency of these clock signals may be considerably lower than that of the clock signals fed from the quartz oscillator to the control means. Due to the fact that the quartz oscillator is turned off during the standby mode, this known control circuit uses, in addition to the quartz oscillator serving as main oscillator, a second oscillator serving as a standby oscillator that is permanently in operation and has a considerably lower oscillation frequency than the main oscillator and a considerably lower power consumption than the main oscillator. In conventional manner, for example an RC oscillator or an IC oscillator is employed as standby oscillator, with a capacitor thereof being periodically charged and discharged with the aid of a current source and a switch.
Such standby oscillators involve problems in so far as the frequency stability thereof is not very good.
SUMMARY OF THE INVENTION
The present invention thus is to make available measures for overcoming this problem. According to the invention, this is achieved by a control circuit with a high power consuming full operation mode and a low power consuming standby mode wherein the timing control for both modes is an inaccurate oscillator timer which is adjusted during every full operation mode by an accurate oscillator timer.
The control circuit according to the invention can be switched to a standby mode of operation during periods of time without control necessity, and during such standby operation can be reset repeatedly to full operation for a short wake-up period each. The control circuit includes a full operation circuit part that is operable only during full operation of the control circuit, and a frequency-stable main oscillator having a relatively high power demand. It comprises a standby circuit part that is operable both in the full mode and in the standby mode of operation and has an adjustable standby oscillator which as such is inaccurate in terms of frequency and consumes little power. The standby oscillator is adjusted during wake-up periods with the assistance of the main oscillator.
In an embodiment of the invention, the full operation circuit part comprises a control means and the standby circuit part contains a frequency control means in which a frequency control signal can be stored, and a wake-up means which is controlled by an output signal of the standby oscillator and by means of which at least the control means and the main oscillator are adapted to be brought into full operation each during the wake-up periods. There is provided a frequency measuring means through which a measurement of the actual oscillator frequency of the standby oscillator can be carried out during each wake-up period. This embodiment comprises a frequency correction means through which the actual oscillator frequency measured during the particular wake-up period is compared to a set oscillator frequency and by means of which a corrected frequency control signal can be generated that is a function of the particular comparison result and can be stored in the frequency control means as new frequency control signal each.
With such a control circuit, the actual frequency of the standby oscillator is thus measured during each wake-up operation and, in case of a deviation of the actual frequency of the standby oscillator from its set frequency, an adjustment of the standby oscillator to the desired set frequency is effected. Due to the relatively short time intervals between the individual wake-up periods, the standby oscillator thus maintains its set frequency with very high reliability despite its inherently poor frequency stability.
In a preferred embodiment of the invention, the control circuit contains a state monitoring means through which, during standby operation of the control circuit, the respective states of predetermined sensors and/or detectors and/or other electrical means can be monitored and the control circuit can be reset to full operation upon detection of predetermined states.
The control circuit may have a microcontroller having at least one interrupt input via which the microcontroller can be reset from standby operation to full operation.
In an embodiment of the invention, the frequency of the standby oscillator may be controllable by means of a digital frequency control signal. When an IC oscillator is employed as standby oscillator, a plurality of differently weighted adjustment current sources may be provided, with the digital frequency control signal determining which ones of the adjustment current sources are turned on each for charging a capacitor of the standby oscillator.
The frequency control means may comprise a frequency control signal register in which the frequency control signal that has arisen during the particular wake-up period from a comparison between actual and set frequencies of the standby oscillator, can be stored and the memory contents of which determine the particular frequency of the standby oscillator by means of a frequency comparator means.
The frequency measuring means may have a time gate means through which, during the respective wake-up period, a time gate having a gate duration depending on the oscillation period actual duration of the standby oscillator is opened, the number of oscillations of the main oscillator occurring during the gate duration is counted and the count thus obtained is compared with a reference count value corresponding to the oscillation period set duration of the standby oscillator.
The control circuit according to the invention is suitable for a central locking system for a motor vehicle, which has several electrical switch contacts which are associated, for example, with locks located in different locations in the motor vehicle and of which at least part changes its switching state upon actuation of the central locking system. The function monitoring means of the control circuit can be used for monitoring the switching states of at least part of the switch contacts. If an alteration of the switching state of at least one of the electrical contact is detected in the standby mode, resetting to full operation is effected.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention shall now be elucidated in more detail by way of embodiments as shown in the drawings.
FIG. 1 shows a block diagram of an embodiment of a control circuit according to the invention.
FIG. 2 shows clock signals of a main oscillator of the control circuit depicted in FIG. 1.
FIG. 3 shows a time gate of the control circuit depicted in FIG. 1.
FIG. 4 shows clock signals of the main oscillator, as taken out with the aid of the time gate.
FIG. 5 shows an embodiment of a standby oscillator that can be used in the control circuit according to FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
The embodiment of a control circuit according to the invention, illustrated in FIG. 1 in the form of a block diagram, comprises as control means a microcontroller μC which is subject to the timing clock control of a main oscillator MOSC which is designed as a quartz oscillator and from which microcontroller μC receives a main clock signal MCLK via a first microcontroller input IN1. In addition thereto, this control circuit comprises a standby oscillator SBOSC generating a standby clock signal SBCLK. The latter is delivered to a wake-up circuit WUP. This circuit, under the control of the standby clock signal SBCLK, periodically generates a wake-up signal and delivers the same to an interrupt input INT of microcontroller μC. The wake-up signal is generated during each n th clock pulse of the standby clock signal SBCLK, in which n may be an arbitrary integer.
The frequency of standby oscillator SBOSC is tunable, with the aid of a digital frequency control signal FCS that can be stored in a frequency control signal register FCR. By changing the memory contents of FCR, the clock frequency SBCLK can be varied.
The control circuit furthermore comprises as frequency measuring means a TIMER communicating with the microcontroller via a data bus DB. The frequency measuring means TIMER comprises a time measurement input ZE connected to the output of an AND circuit A which has a first input E1 connected to the output of main oscillator MOSC, a second input E2 connected to the output of a gate logic GL, and an output O connected to the time measurement input ZE. The gate logic GL has a logic input LE to which is supplied the standby clock signal SBCLK. Within each m th wake-up period duration, in which m may be an arbitrary integer and preferably is 1, gate logic GL generates, under the time control of SBCLK, at a logic output LA a gate signal GATE determining the duration of a time gate TF (FIG. 3) and being supplied on the one hand to the second input E2 of A and on the other hand to a second microcontroller input IN2. During the duration of this gate signal GATE, the AND circuit A allows the main clock signal MCLK (FIG. 2) of the main oscillator MOSC to pass. The frequency measuring means TIMER counts the number of clock pulses of main clock signal MCLK supplied thereto during the particular time gate TF (FIG. 4). At the end of the respective time gate TF, which is reported to microcontroller μC by the gate logic GL via the second microcontroller input IN2, microcontroller μC retrieves from the frequency measuring means TIMER the count obtained at the end of time gate TF, via data bus DB.
Main oscillator MOSC has for example a frequency of 8 MHz and standby oscillator SBOSC has for example a frequency of 32 kHz. Time gate TF, which is closely correlated to the frequency of standby oscillator SBOSC and, for example, has the duration of one clock pulse of SBCLK, thus is capable of containing considerably more clock pulses MCLK in practical application than is shown in FIGS. 2 to 4.
Microcontroller μC has stored therein a set count corresponding to a predetermined set frequency of standby oscillator SBOSC. The count delivered to microcontroller μC at the end of a time gate TF by TIMER, which count corresponds to the respective actual frequency of standby oscillator SBOSC and thus is referred to as actual count, is compared in microcontroller μC to the set count. If the respective actual count differs from the set count, microcontroller μC produces a correction signal and, responsive thereto, a digital frequency control signal FCS which is written into frequency control signal register FCR by microcontroller μC via data bus DB. In addition thereto, the TIMER is reset again to an initial count of 0, for example.
The respective frequency control signal written into frequency control signal register FCR then determines the particular frequency of standby oscillator SBOSC, until a new frequency control signal is delivered to frequency control signal register FCR by microcontroller μC.
FIG. 5 shows a preferred embodiment of a standby oscillator SBOSC suitable for the control circuit according to the invention. This standby oscillator, in a manner known per se, is composed as an IC oscillator, i.e., an oscillator having a capacitor which in periodically alternating manner is charged by means of a current source means and discharged by means of a switch.
The oscillator shown in FIG. 5 comprises a series connection inserted between a supply voltage source UB and a ground terminal GND and comprising a capacitor C and four current sources S1 to S4 connected in parallel to each other. Capacitor C has a first switch SW1 connected in parallel thereto. A circuit point P between capacitor C and current sources S1 to S4 is connected to an input of a comparator COM whose output signal controls the switching state of switch SW1. Current source S1 serves as main current source and is permanently connected to capacitor C. Current sources S2 to S4 serve as adjustment current sources.
Between each of adjustment current sources S2 to S4 and voltage supply source UB, there is connected one of three switches SW2 to SW4. The switching states of switches SW2 to SW4 are controlled by means of switch control signals FCS1, FCS2 and FCS3, respectively, which are various bit positions of frequency control signal FCS stored in frequency control signal register FCR.
Adjustment current sources S2 to S4 deliver current values of different magnitude I 1 , I 1/2 and I 1/4 , respectively, and are weighted in accordance with the binary system.
The oscillator depicted in FIG. 5 operates such that, when switch SW1 is opened, capacitor C is charged with the current at least of main current source S1. The charging voltage of capacitor C increases correspondingly until this charging voltage reaches a predetermined reference value, whereupon comparator COM generates an output signal switching switch SW1 to its conducting state, thus causing sudden discharge of capacitor C. This alternating charging and discharging of the capacitor is repeated periodically, with the steepness of the rise in charging voltage and thus the particular duration of the charging operation being dependent upon the charging current intensity. The latter in turn is dependent upon how many of the adjustment current sources S2 to S4 are turned on by means of the associated switches SW2 to SW4. And this is determined by the respective digital frequency control signal FCS stored in frequency control signal register FCR.
In the embodiment in which the control circuit is used in a motor vehicle, the wake-up circuit WUP may receive inputs from many different sources to wake-up the microcontroller μC on the occurrence of selected actions, for example, it may be utilized at the same time as a monitoring means for monitoring the respective states of predetermined sensors and/or detectors or other electrical means (not shown), for example electrical switch contacts associated with various locks of the motor vehicle, head lights, door positions, air conditioning units, or other electronic circuits in the automobile.
The operation of the control circuit shown in FIG. 1 will now be explained using as one example the case in which the control circuit is used in connection with the control of a central locking system for a motor vehicle.
It is assumed first that the entire control circuit is operating, i.e., in full operation. When no control requirement of the control circuit has been detected by the state monitoring means during a predetermined period of time, for example since either the vehicle in its entirety is not in use or since the central locking system has not been operated for a longer period of time, microcontroller μC is stopped by a stop command in its momentary, current program step and is turned off.
Such turning off has an effect only on microcontroller μC and main oscillator MOSC and possibly on further means of the circuit arrangement that are not shown in FIG. 1. The other circuit parts shown in FIG. 1, namely standby oscillator SBOSC, frequency control signal register FCR, gate logic GL, TIMER, and wake-up circuit WUP are not affected by said turning off, but remain turned on for maintaining the standby operation.
During this standby operation, the standby clock circuit SBOSC, periodically and after specific time intervals as has been described, for example after 1 s each, outputs a signal on line SBCLK to the WUP. Upon the WUP receiving the signal on SBCLK it outputs an interrupt signal on line INT to turn on microcontroller μC via input INT for a respective wake-up period of, e.g., 1 ms, which causes also main oscillator MOSC to be turned on. During the respective wake-up period, a time gate TF is produced by means of gate logic GL, the comparison between actual frequency and set frequency of standby oscillator SBOSC is carried out with the aid of μC, and the new frequency control signal which is a function of the result of this comparison is written into frequency control signal register FCR, which causes a corresponding control operation of switches SW2 to SW4 of standby oscillator SBOSC shown in FIG. 5. After expiration of the wake-up period, microcontroller μC and main oscillator MOSC are turned off again.
If wake-up circuit WUP, with respect to one or several of the contacts monitored by it, detects a change of state during a standby duration, it directly, i.e., without waiting for the next wake-up period, issues an interrupt command, acting as a wake-up signal, via interrupt input INT to microcontroller μC, whereupon the latter and the main oscillator MOSC are turned on and the control circuit is thus reset to full operation. Due to the fact that microcontroller μC is turned off by a respective stop command, microcontroller μC during each wake-up operation resumes its operation in that program step in which it has been turned off before by the stop command.
While the invention has been described with respect for use in an automobile, it may also be used in a circuit, such as a portable computer, printer, or any other circuit having a microcomputer or microprocessor therein which is periodically placed in a sleep mode for power savings. | A control circuit adapted to be switched to a standby mode during periods without control requirement and to be repeatedly reset during the standby mode of operation for a short wake-up period each to a full mode of operation. The control circuit comprises a standby oscillator that is operative also in the standby mode and that is adjusted during wake-up periods. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention relates to suspect apprehension. Specifically, the present invention relates to systems and methods for remotely disabling and/or tracking vehicles employed by fleeing suspects or other persons of interest.
[0003] 2. Description of the Related Art
[0004] Systems for facilitating suspect apprehension are employed in various applications including law enforcement and military operations. Such applications demand efficient mechanisms to facilitate apprehending suspects without undue danger to bystanders, pursuers, or the suspect(s).
[0005] Systems for facilitating suspect apprehension are particularly important during high-speed chases, where fleeing suspects create an extreme safety hazard. Conventionally, pursuing agents, such as law enforcement officers, simply chase the suspect via one or more police vehicles, attempting to corner the suspect or force the suspect to run out of gas. Unfortunately, these methods are undesirably dangerous. Accordingly, more local governments are opting to outlaw high-speed chases and instead, let the suspects escape.
[0006] To reduce the duration of high-speed chases and thereby reduce accompanying risks, road spikes are sometimes employed. However, pursuers must either guess where the suspect will flee and then place spikes accordingly, or they must divert the suspect to the desired road equipped with the spikes. Unfortunately, suspect movement is often unpredictable, and innocent persons may be killed before the fleeing suspect reaches the road spikes. Furthermore, even after hitting road spikes, suspects often continue the chase with flat tires, which may increase danger to innocents, since vehicles becomes less controllable without tires.
[0007] To reduce pressure on pursuing agents to closely trail fleeing suspects, systems for tracking the suspects' locations may be employed. Such systems, such as those disclosed in U.S. Pat. No. 6,246,323, entitled METHOD AND SYSTEM FOR TRACKING A VEHICLE, employ a transmitter embedded in a carrier that sticks on the vehicle when launched at the vehicle. The transmitter broadcasts a signal that enables pursuing agents to track the fleeing vehicle. However, law enforcement agents relying on these systems may be less likely to maintain visual contact with the suspects. Consequently, suspects may more readily escape by parking their vehicles and fleeing. This is particularly true in urban environments, where a fleeing suspect can blend with a crowd and where high-speed chases are more dangerous. This is especially problematic when the fleeing suspect is wanted for a serious crime.
[0008] Furthermore, use of such tagging trackers may not end the chase. If the suspect is a murder or other dangerous criminal that must be apprehended, pursuing agents may still attempt to maintain visual contact with the fleeing suspect. Consequently, the pursuits may remain undesirably dangerous despite the use of the trackers.
[0009] Alternatively, systems for remotely controlling vehicles, as described in U.S. Pat. No. 6,411,887, entitled METHOD AND APPARATUS FOR REMOTELY CONTROLLING MOTOR VEHICLES, and U.S. Pat. No. 6,470,260, of the same title, may sometimes be employed. These systems include a device for sending control signals to control modules contained in the pursued vehicle. Unfortunately, pursued vehicles rarely have such control modules installed, and a clever suspect could conceivably disable such modules before or during the chase.
[0010] The art is crowded with systems that attempt to disable fleeing vehicles. One such system is disclosed in U.S. Pat. No. 5,503,059, entitled VEHICLE DISABLING DEVICE AND METHOD. Unfortunately, such systems often require equipment, such as remote-controlled vehicle-disabling devices, which often do not exist on fleeing suspect vehicles. Accordingly, these devices are not widely used by law enforcement.
[0011] Hence, a long-felt unsolved need remains for an efficient system and method for facilitating apprehending persons fleeing by vehicle while minimizing danger to innocent bystanders and maximizing chances that the suspects are caught.
SUMMARY OF THE INVENTION
[0012] The need in the art is addressed by the system for selectively disabling a vehicle of the present invention. In the illustrative embodiment, the system adapted to prevent high-speed automotive chases. The device includes first mechanism for locating the fleeing vehicle. A second mechanism launches a disabling projectile toward the fleeing vehicle. A third mechanism employs the projectile to disable the vehicle by suffocating an engine of the vehicle or otherwise compromising the fuel/air mixture.
[0013] In a specific embodiment, a fourth mechanism plugs a muffler of the vehicle and includes a muffler-plugging agent incorporated within the projectile. A fifth mechanism guides the projectile toward the muffler and includes an infrared guidance system.
[0014] In a more specific embodiment, the third mechanism includes a gas incorporated within the projectile. The gas is sufficient to stall the vehicle upon or after entering an engine of the vehicle. A sixth mechanism selectively disperses the gas upon or after impact of the projectile with the vehicle. The projectile includes a sticky substance for adhering the projectile to the vehicle. A seventh mechanism directs the projectile into an aperture of the muffler, thereby at least partially plugging the muffler.
[0015] The novel design of the present invention is facilitated by the second and third mechanisms, which employ a projectile to plug a vehicle muffler or air intake and/or to introduce an engine-stalling gas into the engine of the vehicle. Hence, the system may be readily employed to stop most existing automobiles without relying on pre-installed equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a diagram of a system for selectively disabling a vehicle via a muffler-clogging projectile according to an embodiment of the present invention.
[0017] FIG. 2 is a diagram of an alternative embodiment of a system for selectively disabling a vehicle.
[0018] FIG. 3 is a diagram illustrating a muffler-clogging agent suitable for use with the projectiles of FIGS. 1 and 2 .
[0019] FIG. 4 is a diagram illustrating an alternative muffler-clogging agent suitable for use with the projectiles of FIGS. 1 and 2 .
DESCRIPTION OF THE INVENTION
[0020] While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility.
[0021] FIG. 1 is a diagram of a system 10 for selectively disabling a vehicle 18 via a muffler-clogging projectile 12 according to an embodiment of the present invention. For clarity, various components, such as power supplies, amplifiers, integrated circuit chips, and so on, have been omitted from the figures. However, those skilled in he art with access to the present teachings will know which components to implement and how to implement them to meet the needs of a given application.
[0022] The system 10 includes a projectile launch/guidance system 14 in communication with the projectile 12 . The projectile launch/guidance system 14 is adapted to launch and guide the muffler-clogging projectile 12 toward the muffler 16 of the vehicle 18 .
[0023] The projectile launch/guidance system 14 includes an infrared aperture 20 and a laser radar (ladar) system aperture 22 . An Infrared (IR) Focal Plane Array (FPA) 24 of infrared energy detectors is positioned adjacent to the infrared aperture 20 through which infrared energy is received from a scene containing the vehicle 18 . The IR FPA 24 provides input to an IR system 26 , which performs IR image processing of the scene. The IR system 26 provides input to a tracking system 28 . The tracking system 28 also receives input from a ladar system 32 , which receives input from a ladar FPA 30 , which is positioned to receive laser energy via the ladar system aperture 22 . The ladar system 32 also communicates with a laser 40 , which selectively illuminates the scene containing the vehicle 18 via laser pulses 44 . Laser pulses 44 reflecting from the scene containing the vehicle 18 are called laser returns 46 . The laser returns 46 pass through the ladar aperture 22 to the ladar FPA 30 .
[0024] The tracking system 28 provides input to a launch/guidance controller (controller 2 ) 34 , which also receives range input directly from the ladar system 32 . The launch/guidance controller 34 communicates with a launch/guidance transceiver (transceiver 2 ) 36 , which has an antenna 38 for communicating with the projectile 12 via a radio signal 50 . The launch/guidance controller 34 also provides control input to a launcher 42 , which is capable of launching the muffler-clogging projectile 12 .
[0025] In the present specific embodiment, the muffler-clogging projectile 12 includes an IR seeker 56 , which provides input to a projectile controller (controller 1 ) 58 and a projectile transceiver (transceiver 1 ) 54 having an accompanying projectile antenna 52 . The projectile controller 58 provides input to a fuze 62 and projectile-steering actuators 66 , which control projectile steering fins 68 .
[0026] The fuze 62 provides a charge-activation signal to an explosive charge 64 , which is surrounded by a muffler-clogging agent 60 . The fuze 62 may be embedded within the muffler-clogging agent 60 and positioned adjacent to the charge 64 . The charge-activation signal may be a pressure wave or heat generated by an initiating charge (not shown) positioned within the fuze 62 .
[0027] In operation, the projectile launch/guidance system 14 views the scene containing the vehicle 18 through the apertures 20 , 22 via the FPA's 24 , 30 , which detect electromagnetic energy 46 , 48 received from the scene. The construction details of suitable FPA's are known in the art, and one skilled in the art may readily select an appropriate FPA to meet the needs of a given application.
[0028] The FPA's 24 , 30 detect electromagnetic energy and provide electrical signals in response thereto to the IR system 26 and the ladar system 32 , respectively. In the present embodiment, the systems 26 , 32 are imaging systems. The IR system 26 constructs an infrared image of the scene containing the vehicle 18 and muffler 16 based on the infrared energy 48 emanating from the scene. Typically, the muffler 16 will provide a distinct heat signature, which may be readily illustrated by the IR system 26 . Tracking heat emanating from the muffler 16 facilitates targeting at night, where passive visual systems may be compromised.
[0029] The ladar system 32 also constructs an image of the scene containing the vehicle 18 . The ladar system 32 selectively causes the laser 40 to fire the laser pulses 44 toward the vehicle 18 , thereby illuminating the vehicle 18 . The return pulses 46 contain image information about the scene containing the vehicle 18 . Furthermore, by computing the time difference of arrival between when the pulses 44 are fired and the corresponding pulses 46 are received, the distance between the projectile launch/guidance system 14 and the muffler 16 may readily be computed based on the speed of light. Accordingly, the ladar system 32 provides both imaging information and range information.
[0030] Imaging information from the IR system 26 and from the ladar system 32 is provided to the tracking system 28 , which more precisely determines the position of an aperture 82 of the muffler 16 therefrom. The tracking system 28 may include matched filters, velocity filters, and/or other modules (not shown) to facilitate target detection, i.e., muffler-aperture location detection. Precise target location information or a prediction thereof is forwarded to the launch/guidance controller 34 in real time. Muffler aperture range information is also forwarded from the ladar system 32 to the launch/guidance controller 34 .
[0031] The launch/guidance controller 34 may receive additional input from a user-interface (not shown), which may be employed by operators to selectively enable and/or control the operation of the projectile launch/guidance system 14 . When the projectile launch/guidance system 14 is enabled, the launch/guidance controller 34 determines when the muffler aperture 82 (target) is within range of the projectile launch/guidance system 14 based on range information from the ladar system 32 .
[0032] When the target 82 is within adequate range of the projectile launch/guidance system 14 , the launch/guidance controller 34 activates the launcher 42 , which launches the muffler-clogging projectile 12 toward the muffler 16 . The projectile launch/guidance system 14 may be mounted on a gimbal (not shown) to facilitate properly orienting the launcher 42 so that the projectile 12 may be more effectively aimed at the muffler 16 . Furthermore, the projectile launch/guidance system 14 may be mounted on a pursuing vehicle, such as a helicopter, police car, or military vehicle. Those skilled in the art with access to the present teachings will know how to design and implement or otherwise obtain user-interfaces and gimbals to meet the needs of a given application and without undue experimentation.
[0033] In an alternative implementation, the launcher 42 is mounted separately from the projectile launch/guidance system 14 , such as on a helicopter or along the side of a road. Such a remotely positioned launcher may be wirelessly controlled.
[0034] When the projectile 12 is flying toward the muffler 16 , the IR seeker 56 on the projectile 12 zeros in on the location of the muffler 16 . The projectile controller 58 selectively controls the steering fins 68 via the steering actuators 66 based on information received from the IR seeker 56 and based on information received by the projectile transceiver 54 from the projectile launch/guidance system 14 . The transceiver 52 may also forward information from the IR seeker 56 to the launch/guidance controller 34 on the launch/guidance system 14 to enhance guidance controls forwarded to the projectile controller 58 from the launch/guidance controller 34 via the transceivers 36 , 54 .
[0035] In the present illustrative embodiment, the projectile controller 58 employs an algorithm to optimally combine information from the IR seeker 56 and the transceiver 54 to accurately steer the projectile 12 . Those skilled in the art may readily implement customized algorithms to combine the information from the transceiver 54 and the IR seeker 56 as required for a given application. In some implementations, the transceivers 54 and 36 are omitted, and projectile steering after the projectile 12 is launched is performed solely based on information received by the projectile controller 58 from the IR seeker 56 . Furthermore, those skilled in the art will appreciate that the IR seeker 56 may be implemented as another type of seeker, such as a hybrid infrared, sonar, microwave, radar, and/or ladar seeker.
[0036] The transceiver 54 may act as a vehicle-locating device upon sticking to or lodging within the muffler 16 . The transceiver 54 may incorporate Global Positioning System (GPS) functionality so that the location of the vehicle 18 may be readily tracked via location signals transmitted from the projectile transceiver 54 .
[0037] Those skilled in the art will appreciate that other types of targeting technologies, such as sonar techniques, may be employed without departing from the scope of the present invention. For example, the ladar equipment 30 , 32 , 40 on the projectile launch/guidance system 14 may be replaced with radar equipment without departing from the scope of the present invention. Furthermore, the IR seeker 56 may be replaced with another type of seeker, or the seeker 56 may be omitted.
[0038] In the present embodiment, the projectile controller 58 receives timing information from the projectile launch/guidance system 14 via the projectile transceiver 54 . The timing information is based on the initial measured distance between the projectile launch/guidance system 14 and the muffler 16 as measured by the ladar system 32 and is based on the kinematic properties of the projectile flight, which are approximately governed by the following well-known equation:
P = 1 2 a t 2 + v o t + P o , [ 1 ]
where t is time; P is the current position; a represents projectile acceleration; v o is the initial velocity; and P o is the initial position of the projectile 12 . The timing information is employed by the projectile controller 58 to selectively trigger activation of the fuze 62 , which detonates the charge 64 , thereby dispersing the muffler-clogging agent 60 on, over, or within the muffler 16 .
[0040] The projectile controller 58 may employ equation (1) in combination with initial range information from the launch/guidance system 14 to compute the distance between the projectile 12 and the muffler 16 to facilitate timing of activation of the fuze 62 . Other timing methods may be employed without departing from the scope of the present invention.
[0041] In some implementations, the muffler-clogging agent 60 is designed to disperse over the muffler 16 , thereby covering the muffler aperture, as discussed more fully below. In other applications, the muffler-clogging agent 60 lodges within the muffler 16 or aperture thereof.
[0042] In an alternative implementation, the fuze 62 does not receive input from the controller 58 , and instead is a microelectromechanical (MEMS) or nanosystems fuze that arms upon launch setback acceleration and triggers upon impact with the muffler 16 . An exemplary MEMS safe-and-arm device is disclosed in U.S. Pat. No. 6,167,809, entitled ULTRA-MINATURE, MONOLITHIC MECHANICAL SAFETY-AND-ARMING DEVICE FOR PROJECTED MUNITIONS, by Charles H. Robinson et al, the teachings of which are herein incorporated by reference. Those skilled in the art with access to the present teachings may readily implement a suitable fuze without undue experimentation.
[0043] Furthermore, in some implementations, the muffler-clogging projectile 12 is fitted with wings that may have accompanying control surfaces (not shown) on the projectile 12 to enable relatively slow projectile flight toward the muffler 16 before the muffler-clogging agent 60 is dispersed on or within the muffler 16 . Relatively slow projectile flight in combination with winged control surfaces may provide more time for the projectile 12 to seek and steer toward the muffler 16 and may enhance safety, especially when hard-surfaced projectiles are employed. Implementation of slow-flying projectiles or fast-flying projectiles is application-specific and may be determined by those skilled in the art to meet the needs of a given application.
[0044] The steering fins 68 may be replaced by another type of actuator, such as micro thrusters or charges that are selectively detonated to create desired directional changes in the motion of the projectile 12 . An exemplary micro-actuator is disclosed in U.S. Pat. No. 6,105,503, by Baginski, issued Aug. 22, 2000, entitled ELECTRO-EXPLOSIVE DEVICE WITH SHAPED PRIMARY CHARGE, the teachings of which are herein incorporated by reference.
[0045] The projectile 12 may be constructed in a gelatinous housing so that in the unlikely event that the projectile misses the muffler 16 , it will not result in injury or other collateral damage.
[0046] Hence, the system 10 is an effective system for disabling a vehicle, such as the truck 18 , during pursuit or a high-speed chase. This system 10 improves upon the current state of the art by not requiring special equipment to be installed on the fleeing vehicle and by not allowing the criminal to park and escape before the police converge on the scene. By firing the heat-seeking projectile 12 toward the tailpipe 16 of the automobile 18 and thereby plugging the tailpipe and suffocating the engine, the engine of the vehicle 18 stalls. The projectile 12 may be contained in a glue or other sticky gelatinous material that disposes around the tailpipe 16 .
[0047] Alternatively, a detonator 62 , 64 within the projectile 12 activates in response to the projectile travel time with reference to range information determined by the launch/guidance system 14 to determine just the right time to detonate, releasing a wall of clogging-agent from within the projectile 12 , which is sufficient to coat the muffler 16 , sealing the muffler aperture 82 . Various other projectiles may be employed without departing from the scope of the invention. Side firing of the projectile 12 is enabled to account for horizontally mounted tail pipes (not shown). However, the clogging-agent 60 may still wrap around the side of such tailpipes when fired from the rear of the associated vehicles and may be sufficient to stop or at least slow the suspect vehicle 18 .
[0048] FIG. 2 is a diagram of an alternative embodiment of a system 10 ′ for selectively disabling the vehicle 18 . The alternative muffler-clogging projectile 12 ′ is similar to the muffler-clogging projectile 12 of FIG. 1 , with the exception that the IR seeker 56 of FIG. 1 is omitted, and the projectile transceiver 54 and accompanying antenna 52 of FIG. 1 are replaced with a receiver 54 ′ and antenna 52 ′ in FIG. 2 . The infrared and ladar components 20 - 32 , 40 of the launch/guidance system 14 of FIG. 1 are omitted in the system 10 ′ FIG. 2 .
[0049] The alternative launch/guidance system 14 ′ employs an optical aperture 22 ′ for receiving optical energy 74 from the scene containing the muffler 16 . An optical FPA 70 converts the received optical energy 74 into an electrical signal, which is forwarded to an optical imaging system 72 . The optical imaging system 72 constructs an image of the vehicle 18 and muffler 16 based on the received optical energy 74 . The resulting image information is forwarded to a boresighting system 72 .
[0050] The boresighting system 72 includes a user-interface (not shown) that enables a user to guide the projectile 12 ′ toward the muffler 16 by aligning a boresight (crosshairs) with the muffler 16 . The boresight location of the image information received from the optical imaging system 72 is employed by an accompanying launch and guidance controller 34 ′ to generate control signals 50 ′ effective to guide the muffler-clogging projectile 12 ′ toward the muffler 16 when the location of the muffler 16 is aligned with the boresight. The control signals are transmitted via a launch/guidance transmitter 36 ′ and accompanying antenna 38 ′. The projectile receiver 54 ′ then forwards the control signals to the projectile controller 58 ′, which controls activation of the fuze 62 and fin steering actuators 66 accordingly in response thereto.
[0051] The launcher 42 may be manually activated via the user-interface of the boresighting system 72 . The projectile launch/guidance system 14 ′ may be mounted on a manually controlled gimbal and/or an automatically controlled gimbal (not shown) to facilitate initial projectile aiming.
[0052] Those skilled in the art may employ other types of guidance systems and techniques, such as Tube-launched Optically-tracked, Wire-guided (TOW) methods, which may employ beacons placed on the projectile 12 ′. Furthermore, guidance systems employing Inertial Reference Units (IRU's) or Inertial Measurement Units (IMU's) may be employed without departing from the scope of the present invention. In addition, the optical components 22 ′, 70 , 72 may be replaced with other types of components, such as infrared components. Those skilled in the art will know which components to implement to meet the needs (such as budget requirements) of a given application.
[0053] Alternative projectiles may be guided in accordance with various other well-known guidance techniques, such as those disclosed in U.S. Pat. No. 6,565,036, entitled TECHNIQUE FOR IMPROVING ACCURACY OF HIGH SPEED PROJECTILES, the teachings of which are herein incorporated by reference, without departing from the scope of the present invention.
[0054] FIG. 3 is a diagram illustrating a muffler-clogging agent 60 suitable for use with the projectiles 12 , 12 ′ of FIGS. 1 and 2 . With reference to FIGS. 1 and 3 , the muffler-clogging agent 60 is selectively dispersed from the projectile 12 in response to activation of the charge 64 when the projectile 12 is sufficiently close to the muffler 16 .
[0055] In the present specific embodiment, the muffler-clogging agent 60 includes plural beads 80 , which can readily enter an aperture 82 of the muffler 16 . The beads 80 enter a main body 84 of the muffler 16 via the muffler aperture 82 and begin to expand. The beads 80 each include a small gas cartridge 90 in communication with a micro-fuze 62 ′, which are surrounded by a durable balloon, foam, or other material that expands upon activation of the small gas cartridge 90 in response to an activation signal from the fuze 62 ′. The fuze 62 ′ may be a temperature-sensitive fuze that triggers in response to heat from the muffler 16 . Alternatively, the fuze 62 ′ arms in response to setback acceleration from the launch of the projectile 12 and/or from activation of the dispersing charge 64 and then activates upon sensing impact with the muffler 16 . Alternatively, the fuze 62 ′ incorporates a receiver (not shown) and is remotely activated via the launch/guidance system 10 . When the fuze 62 ′ activates, it causes the small gas cartridge 90 to release pressurized gas, which expands the surrounding coating 92 , thereby expanding the beads 80 . The beads lodged within the muffler body 84 are designed to sufficiently expand to block the muffler aperture 82 .
[0056] In the present embodiment, some of the beads 80 are designed to rupture once inside the muffler body 84 . These beads contain a special gas within the small gas cartridge 90 . This special gas is sufficient to trigger engine stall when it diffuses back through the muffler system to the engine cylinders (not shown) of the vehicle 18 . A suitable gas may include a trifluoroidomethane mixture with an inert atmospheric buoyant gas such as helium as disclosed in U.S. Pat. No. 5,848,650, VEHICULAR ENGINE COMBUSTION SUPPRESSION METHOD, by Brian B. Brady, the teachings of which are herein incorporated by reference.
[0057] Any diffusion of such gas back to the cylinders will promote engine stall. Furthermore, the projectile 12 may be fired at the front of the vehicle 18 being pursued. Impact with the cars front grill will trigger the fuze to release the gas, which will pass into the engine air intake, thereby stalling the engine.
[0058] In some implementations, the beads 80 are designed to penetrate the walls of the muffler body 84 rather than entering through the aperture 82 . When the beads 80 expand upon penetrating the muffler body 84 , they plug the holes created therein. In other implementations, the projectile 12 passes to the side or underneath the muffler and ejects the beads 80 sideways or upward to facilitate plugging side-facing or downward-facing tailpipes.
[0059] In an alternative implementation, the projectile 12 is launched toward a front of the vehicle 18 . The clogging agent 60 then disperses within the air intake of the vehicle 18 or attaches to the front grill, which triggers release of the engine-stalling gas from the gas cartridge 90 . The engine-stalling gas will then suffocate the engine of the vehicle 18 . Alternatively, expansion of the beads 80 may sufficiently plug the air intake to cause the vehicle 18 to stall.
[0060] Hence, embodiments of the present invention often cause the engine of a fleeing vehicle, such as the vehicle 18 , to stall by controlling the fuel/air mixture in the combustion chambers of the accompanying engine via direct suffocation by plugging the muffler 16 or air intake (not shown) and/or by gas that suffocates the engine or otherwise compromises the fuel/air mixture.
[0061] In an alternative embodiment, the muffler-clogging agent 60 may be built into the muffler 16 or air intake and remotely activated by law-enforcement other pursuing agents. Pre-positioning the disabling mechanism 60 within the muffler 16 or air intake decreases tampering likelihood, as it cannot be seen unless the muffler 16 is destroyed. Activation may be implemented via a directional signal transmitted by authorities and received by a receiver (not shown) included in the fuze 62 ′. By aiming the directional signal at the muffler 16 , authorities may selectively disable the desired automobiles even when they are positioned among several other automobiles. Various directional signals that may be employed include laser beams, microwave beams, and so on. In implementations employing laser beams, the fuze receiver (not shown) will likely include a photodetector (not shown) responsive to a particular beam signature. The photodetector will be positioned within the muffler 16 so that laser light can reach the detector. This may require use of reflective surfaces interior to the muffler 16 .
[0062] FIG. 4 is a diagram illustrating an alternative muffler-clogging agent 60 ′ suitable for use with the projectiles of FIGS. 1 and 2 . With reference to FIGS. 2 and 4 , the clogging agent 60 ′ includes paddies 80 ′ of a sticky/pliable substance sufficient to stick to the muffler 16 and seal the muffler aperture 82 . The paddies 80 ′ may be constructed from hardening glue that hardens quickly when heated by the muffler 16 . In some applications, the paddies 80 ′ may be made sufficiently large to coat the entire rear end of a fleeing vehicle, such as the vehicle 18 of FIGS. 1 and 2 , including the muffler 16 . In systems employing such large paddies, projectile guidance and launch control mechanisms may be less stringent, due to a larger margin for error. By selectively detonating the charge 64 to release the muffler-clogging agent 60 ′ from an accompanying alternative projectile 12 ″ within a predetermined range of the muffler 16 , the effective surface area of the clogging agent 60 ′ expands to ensure that the muffler 16 is properly coated to block exhaust gases from exiting the muffler 16 .
[0063] Thus, the present invention has been described herein with reference to particular embodiments for particular applications. Those having ordinary skill in the art and access to the present teachings will recognize additional modifications, applications, and embodiments within the scope thereof. `It is therefore intended by the appended claims to cover any and all such applications, modifications and embodiments within the scope of the present invention.
[0064] Accordingly, | A system for selectively disabling a vehicle. In the illustrative embodiment, the system adapted to prevent high-speed automotive chases. The system includes a first mechanism for locating vehicle to be disabled. A second mechanism launches a disabling projectile toward the vehicle. A third mechanism employs the projectile to disable the vehicle by suffocating an engine of the vehicle or otherwise compromising the fuel/air mixture. In a specific embodiment, and an infrared guidance system guides the projectile toward a muffler of the vehicle, and a muffler-plugging agent incorporated within the projectile plugs a muffler. | 5 |
FIELD OF THE INVENTION
[0001] This invention pertains to apparatus and method for the deflection of a tubular string which may be suspended from a drilling or service rig or platform.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] FIG. 1 illustrates a side elevated view of the lower portion of an offshore installation utilizing the deflector apparatus according to the present invention;
[0003] FIG. 2 illustrates a side elevated, diagrammatic view of a prior art system involving a selected portion of the installation of the embodiment illustrated in FIG. I with a diver and winch line in use intending to be used to be used to laterally shift the upper portion of a separated tubular string;
[0004] FIG. 3 illustrates a side elevated view of an alternative prior art system involving a whipstock that has been speared into an abandoned well pipe;
[0005] FIG. 4 illustrates a cross-sectional elevated side view of a deflector sub according to the present invention;
[0006] FIG. 5 illustrates an exploded, elevated perspective view of an alternative embodiment of a deflector sub according to the present invention;
[0007] FIG. 6 illustrates a longitudinal, cross-sectional view of the embodiment illustrated in FIG. 5 according to the present invention;
[0008] FIG. 6A illustrates an end plan view of the embodiment illustrated in FIG. 6 according to the present invention;
[0009] FIG. 6B illustrates an enlarged, detail view, partly in cross section of the nozzle-receiving portion of the deflector sub body illustrated in FIG. 6A according to the present invention;
[0010] FIG. 7 illustrates a side view, partially cut away, of an alternative embodiment of the deflector sub according to the present invention;
[0011] FIG. 8 illustrates a side elevated, diagrammatic view of a tubular string deflected by a fluid jet according to the present invention;
[0012] FIG. 9 illustrates a side elevated, diagrammatic view of the embodiment illustrated in FIG. 8 further illustrating a second tubular being lowered over a deflected tubular string according to the present invention;
[0013] FIG. 10 illustrates a side elevated, diagrammatic view of a pair of concentric tubulars being pushed into the seabed according to the present invention;
[0014] FIG. 11 illustrates a side elevated view of the internal tubular string illustrated in FIG. 10 having been removed according to the present invention;
[0015] FIG. 12 illustrates a side elevated view of an alternative embodiment with the exterior tubular illustrated in FIG. 10 being in place during the deflection process according to the present invention;
[0016] FIG. 13 illustrates a side cut away, elevated view of a jet nozzle switching apparatus, with a piston in a first position, according to the present invention;
[0017] FIG. 14 illustrates a side cut away, elevated view of an alternative embodiment with a drop ball in place, with a piston in a first position, according to the present invention;
[0018] FIG. 15 illustrates a side cut away, elevated view of the embodiment illustrated in FIG. 13 with the piston in a second position according to the present invention;
[0019] FIG. 16 illustrates a side cut away, elevated view of the embodiment illustrated in FIG. 15 with the drop ball expelled according to the present invention;
[0020] FIG. 17 illustrates a side cut away, elevated view of the embodiment illustrated in FIG. 16 further illustrating a drill bit according to the present invention;
[0021] FIG. 18 illustrates a side cut away, elevated view of the embodiment illustrated in FIG. 17 with the nozzle switching apparatus drilled out according to the present invention; and
[0022] FIG. 19 illustrates an elevated, pictorial view of a closed end drive shoe according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] It should be understood that the description herein below may use the terms drill string, pipe string, or the more general term tubular or tubular string interchangeably without intention of limitation. It should be further understood that the device and method described herein can be applied to tubulars other than drill string, casing, or tubing.
[0024] FIG. 1 illustrates the lower portion of a typical fixed offshore platform 1 . It is well known in the art that the platform structure stands in the seabed B, is preferably anchored in a conventional manner, and preferably has vertically distributed braces such as illustrated by braces 1 a - d . It is further well known that the platform comprises a plurality of “slots” through which one or more wells can be drilled. Typically, guide sleeves 15 are mounted to the braces 1 a - 1 d and are substantially vertically aligned with the “slots”. Typically, tubulars, used for drilling and production operations are lowered through the “slots” and the corresponding vertically aligned guide sleeves 15 . Such slots and guide sleeves are conventional and well known in this art.
[0025] It is well known that due to size constraints of the platform 1 , the number of “slots” is limited. It is further known that if a wellbore, which corresponds to a particular “slot” and its vertically aligned guide sleeves 15 becomes unuseable, that “slot” also becomes unuseable unless the tubular string, which is to be lowered through the unuseable “slot” can be deflected, from a substantially vertical position, in order to position a new wellbore proximate the unuseable wellbore. It is still further well known, in the art, that a wellbore becomes unuseable for a variety of reasons, including but not limited to, the existing well being depleted, or to stuck tubulars or tools, adverse borehole conditions, and the like. Typically, in an unuseable wellbore, the tubulars are cut off below the mudline and are abandoned for the purposes of the drilling and/or production operations. Typically, after the unuseable wellbore is abandoned, all tubulars are removed from the corresponding “slot” and its vertically aligned guide sleeves 15 . Therefore, the “slot” is only unuseable from the point of view of utilizing a substantially vertical tubular string.
[0026] Still referring to FIG. 1 , when a “slot” is to be recovered, a new tubular string 2 is lowered through the particular “slot” and must be deflected, in a substantially horizontal direction, to bypass the unuseable wellbore. According to the present apparatus, this deflection is preferably accomplished by utilizing a jet sub 3 b as further described herein below.
[0027] FIGS. 2 and 3 illustrate a pair of prior art systems for attempting the tubular string deflection necessary for the “slot” recovery. FIG. 2 illustrates the use of a diver 4 B to secure a winch line or cable 4 a to the platform 1 in an attempt to deflect a pipe 5 in a substantially horizontal direction. A pulley 4 is secured to the platform 1 . Line 4 a hooks around the pipe 5 and pulley 4 and leads to the surface and a winch on the platform. However, this method for deflecting a pipe string presents several problems including the fact that underwater diving operations are inherently risky and weather conditions must be acceptable for divers to operate. Therefore, the procedure is often suspended during inclement weather conditions causing unpredictable delays to the offshore operations.
[0028] FIG. 3 illustrates using a whipstock 6 which is typically speared into the top of an existing pipe EP that has been cut off below the mud line. The whipstock wedge surface or trough 6 b serves to guide and deflect the descending pipe string 5 horizontally. However, this method for deflecting a pipe string also presents several problems including difficulty in stabbing the whipstock into the existing pipe and the probability that the tubular string will permanently separate from the whipstock.
[0029] FIGS. 4-7 illustrate embodiments of the deflector sub 3 b , according to the present invention. FIG. 4 illustrates the basic structure and operation of the deflector sub 3 b . Preferably, the deflector sub 3 b has a closed end 19 . However, it should be appreciated that the deflector sub 3 b does not have to be positioned at the lowermost end of the tubular string 3 , illustrated in FIG. 1 . The deflector sub 3 b may be positioned uphole or behind additional subs or devices ( FIG. 7 ). It should be further appreciated that the deflector sub 3 may comprise various top and bottom connections, such as, but not limited to, box and pin connections respectively, and as such, the closed end 19 may be a separate structure attached to the deflector sub 3 b by threaded attachment, welding, or any other means of conventional attachment or may be located downhole of the deflector sub 3 b.
[0030] Preferably, pumps, or other fluid driving devices, such as the rig pumps may push or propel seawater or other fluid into the tubular string 3 in the general direction indicated by the arrow 17 . The selection of the fluid, being pumped into the tubular string 3 may be dependent on the environment, particularly the environment into which the fluid will be discharged. Preferably, the seawater, or other fluid, is pumped through the tubular string 3 and into the deflector sub 3 b.
[0031] Preferably a jet nozzle 3 b 2 is positioned in the sidewall of the deflector sub 3 b and becomes the outlet for the seawater or other fluid being pumped through the deflector sub 3 b . As the fluid exits through the nozzle 3 b 2 it will produce a fluidjet 3 b 1 . The fluidjet 3 b 1 , in turn, preferably produces a thrust 3 b 3 , in a substantially opposite direction from the fluid jet 3 b 1 and thus moves the deflector sub in the direction of the thrust 3 b 3 . It should be appreciated that the amount of pressure in the bore of the tubular string 3 and the nozzle 3 b 2 size influences the amount of the thrust force 3 b 3 , which in turn substantially determines the amount of deflection of the tubular string 3 . It should be appreciated, by those skilled in the art, that nozzle 3 b 2 is typically a commercially available item and can be found in a variety of sizes. However, the utilization of non-commercial or non-conventional nozzle sizes should not be viewed as a limitation of the present apparatus or method.
[0032] FIG. 5 illustrates further detail of the deflector sub 3 b which preferably comprises a deflector sub body 16 , nozzle 3 b 2 , O-ring 18 , and retaining ring 20 . It should be appreciated that nozzle 3 b 2 , O-ring 18 , and retaining ring 20 , whether commercially available or specifically manufactured for a particular application, are well known in the art and will not be described in detail herein. FIGS. 6 and 6 A illustrate cross-sectional, longitudinal and end views, respectively, of deflector sub body 16 . Orifice 22 is preferably machined in the wall of the deflector sub body 16 for receiving the nozzle 3 b 2 . FIG. 6B is an enlarged view of orifice 22 in the wall of the deflector sub body 16 .
[0033] FIG. 7 illustrates an alternative embodiment of the invention in which deflector sub 3 b is installed behind or uphole from a bit sub 13 located at the end of tubular string 3 . Bit sub 13 is preferably plugged at its lower end 14 in order to allow fluid and pressure, in the drill string or tubular string 3 , to discharge through nozzle 3 b 2 . The guide tubular 3 is illustrated as passing beside a bay brace 7 which resides on the exterior of the guide sleeve 15 through which the unusable wellbore is associated. The guide sleeve 15 is located on the lowermost horizontal rig brace id illustrated in FIG. 1 .
[0034] In recovering a “slot”, a drill string or tubular string 3 is preferably lowered, through the “slot” to be recovered and at least some of its corresponding vertically aligned guide sleeves 15 , to a point about three to four feet above the sea floor. It should be understood that the target depth can vary depending on several factors including, but not limited to, the overall ocean depth, speed of currents, amount of desired deflection, and the size/weight of the guide string. Thus, it should be appreciated that in more adverse conditions, the deflection of the tubular string 3 may need to be initiated earlier or later (i.e. further from or closer to the sea floor) in order to accomplish the desired deflection or to avoid other objects such as, but not limited to, other drill strings, or other drilling related operations. The position of tubular string 3 may then be verified with a measurement device such as a gyroscope. The tubular string 3 is then preferably deflected by energizing a deflector sub 3 b which is preferably attached to the end of the tubular string 3 .
[0035] FIG. 8 illustrates tubular string 3 being deflected by the side thrust 3 b 3 being produced by the fluid jet 3 b 1 . FIG. 8 further illustrates an unuseable well bore 21 (the wellbore 21 being unuseable as described herein above). The deflection, of the tubular string 3 , preferably causes the tubular string 3 to bypass at least the lower most guide sleeve 15 and an unusable wellbore 21 thus recovering the previously unuseable “slot” associated with its vertically aligned guide sleeve 15 and unuseable wellbore 21 . While tubular string 3 is deflected as illustrated, it is then preferably inserted or speared into the mud or sea floor B along line 3 c . It should be understood that line 3 c is preferably deflected, at some desired angle, from a vertical axis passing through the recovered “slot” and its vertically aligned guide sleeves 15 and the unuseable wellbore 21 .
[0036] After the tubular string 3 has been inserted or speared into the sea floor B mud line ( FIG. 9 ), the pumping of seawater is preferably stopped and measurements are taken to verify the position of the deflected drill string or tubular string 3 . The tubular string 3 may then be further lowered until it preferably supports its own weight axially. It should be appreciated that the tubular string 3 will substantially sink through the mud or sediment bottom due to its own weight. It should be appreciated that as the drill pipe or tubular string 3 is lowered further into the seabed B, it will preferably retain its deflected position and not shift in a horizontal direction to its pre-deflected vertically aligned position. The tubular string 3 may then be disconnected at the rotary table (not illustrated) on the platform, leaving a portion of the string protruding through the rotary floor (not illustrated). Another pipe or tubular string 2 ( FIG. 9 ) may then be lowered over the deflected tubular string 3 .
[0037] FIG. 9 illustrates the drive pipe or tubular string 2 installed, preferably slid over the deflected tubular string 3 . FIGS. 9, 10 , and 12 illustrate the tubular string 2 and the deflected tubular string 3 being in a substantially concentric relationship. However, this is optional since in order to maintain such a substantially concentric relationship some type of centralization device (not illustrated), such as a conventional tubular centralizer, would have to be used. The deflected tubular string 3 preferably acts as a guide string to deviate the pipe string or tubular string 2 as it is lowered, over the deflected tubular or tubular string 3 , to the sea floor B. The pipe string or tubular string 2 will preferably be thrust into the mud below mud line as illustrated in FIG. 10 . The tubular string 3 may then be withdrawn from inside the pipe or tubular string 2 , as shown in FIG. 11 . It should be appreciated that the conductor bay brace 7 may also aid in the offset alignment of the drive pipe or tubular string 2 . The conductor bay brace 7 will preferably aid in preventing the drive pipe or tubular string 2 from moving in a substantially horizontal direction toward the unuseable well bore 21 .
[0038] FIG. 12 illustrates an alternative embodiment similar to that illustrated in FIG. 8 except that both the tubular string 3 , with the deflector sub 3 b , and pipe string 2 are installed/lowered together to a desired position above the seabed B. It should be understood that the tubular string 3 is installed/lowered while positioned in the throughbore of the pipe string 2 . As described herein above, pumps may be activated to cause flow through the fluid jet 3 b 1 thus producing a side load 3 b 3 and deflecting both the tubular string 3 and tubular string 2 . When deflected, both the tubular string 3 and tubular string 2 may be dropped/inserted into the mud to secure the deflected position. Further, as illustrated in FIG. 11 , the inner tubular string 3 can be retrieved from the inner bore of the drive pipe or tubular string 2 .
[0039] FIGS. 13-18 show another embodiment of a deflector sub 3 b . This embodiment will preferably allow the deflector sub to deflect the tubular string, as described herein above, and then redirect the jet flow from a side nozzle to a bottom nozzle or aperture to aid in the insertion of the drill pipe or tubular string 3 into the seabed B or “glance” off other obstructions. FIG. 13 illustrates the nozzle switching apparatus 23 which may be housed in a tubular section 8 . It should be appreciated that the tubular section 8 may be attached to the end of tubular string 3 , a pipe, or other tool or tubular as necessary in a manner similar to that of the deflector sub 3 b described herein above. Preferably, the nozzle switching apparatus 23 comprises a drillable material such that the nozzle switching apparatus 23 will not restrict further drilling operations. It should be appreciated that the nozzle switching apparatus 23 may be used as part of a guide string, wherein a larger tubular string is installed over it, or the apparatus 23 may be utilized to guide and deflect the larger tubular. Still referring to FIG. 13 , the nozzle switching apparatus further comprises a guide 8 b which is preferably configured to guide the piston 9 . In its first position, the piston 9 , having an upper surface (unnumbered) tapered inwardly towards channel 9 a , isolates the bore 8 a , of the tubular section 8 from a lower cavity 12 . The piston 9 preferably comprises a plurality of grooves 9 c , disposed about the piston 9 , which may engage corresponding ridges 8 d , disposed about the inner circumference of the lower portion of the tubular section 8 . The engagement of the ridges 8 d with the grooves 9 c will preferably prevent rotation of the piston 9 when it is necessary to drill out the nozzle switching apparatus 23 (See FIGS. 15-17 ). The lower most portion of the tubular section 8 preferably comprises an end 8 c preferably having an opening 8 f , which may be circular or non-circular, as desired.
[0040] The piston 9 is preferably configured with a central channel 9 a bored in a substantially longitudinal direction to intersect with a cross bore 9 b which passes through the piston 9 in a substantially radial direction. In the first position, the piston 9 is releasably secured such that the cross bore 9 b is in fluid communication with a nozzle 8 e . It should be understood that the piston 9 may be held in the first position by a variety of attachment means including, but not limited to shear screws, set screws, ridges, frangible supports, pins, rivets, screws, bolts, specific tolerance fits or a variety of other conventional retention means.
[0041] As with the deflector sub 3 b , preferably a fluid, such as seawater, is pumped into the nozzle switching apparatus 23 to activate the jet flow J 1 by pumping or propelling the fluid through the nozzle 8 e . It should be understood that the fluid is pumped through the pipe or tubular string which extends from the tubular section 8 to the drilling rig or other drilling structure. As the fluid is pumped through the bore 8 a of the tubular section 8 , it will preferably enter the central channel 9 a , move into the cross bore 9 b , and be exhausted through the nozzle 8 e to produce the jet J 1 . The jet J 1 will preferably produce a thrust force in a similar manner to the jet 3 b 1 thus causing the tubular 8 and any attached tubular string to deflect in a direction substantially opposite the nozzle 8 e.
[0042] When the desired deflection is achieved and/or it is desired to switch operation from the side nozzle 8 e to the bottom nozzle or aperture 8 f , a ball 10 or other stopper is preferably dropped down the bore of the tubular, attached to the tubular section 8 , to close channel 9 a as illustrated in FIG. 14 . With the seawater still being pumped into the bore 8 a , the pressure builds up against the top of piston 9 and preferably forces the piston 9 downward to a second position as illustrated in FIG. 15 . It should be appreciated that the pressure increase, which preferably occurs due to the ball or stopper 10 blocking channel 9 a , will shear or break any support maintaining the piston 9 in its initial position and thus allowing for its downward travel. After the piston 9 moves from the first position, cross bore 9 b will no longer communicate with the nozzle 8 e . In the second position, cross bore 9 b will preferably open to the cavity 12 .
[0043] After the piston 9 has moved to the second position, the pressure in bore 8 a is further raised to pump the ball 10 through the central channel 9 a and the cross bore 9 b to permit flow through the bottom hole 8 f , as illustrated in FIG. 16 . It should be understood that ball 10 may be comprised of a variety of materials including, but not limited to, elastomeric, plastic, or frangible materials such as to allow the ball 10 to deform or break in order to pass through the central channel 9 a . After the ball 10 is pushed out of the piston 9 , as illustrated in FIG. 16 , any flow though the bore 8 a is preferably directed through the bottom hole 8 f to aid in reducing interference from mud and sediment which is preferably loosened or removed by the flow through the bottom hole 8 f . It should be appreciated that the bottom hole 8 f can also be configured to accept a nozzle, such as 8 e or 3 b 1 to produce a more forceful jet flow for reducing the interference.
[0044] FIG. 17 illustrates an embodiment wherein the interior components of the tubular section 8 and the attached tubular string are ready to be drilled out for subsequent activity. A milling or drilling assembly 11 , which may be commonly run on a drill string, includes at least one cutter insert 11 a . It should be understood, by those in the art, that a conventional milling or drilling assembly 11 will preferably drill or mill out substantially all material attached to the inside diameter of tubular 8 . FIG. 18 illustrates the pipe string or tubular 8 after the drilling operation has been carried out. Typically, the side nozzle 8 e can remain unplugged.
[0045] Referring now to FIG. 19 , the lowermost end of the drive pipe or tubular string 2 will preferably, comprise a drive shoe 26 which may be integral to the lowermost section of the drive pipe or tubular string 2 or may be a separate drive shoe attached to the lowermost section of the drive pipe or tubular string 2 . It should be appreciated that the attachment of the drive shoe 26 is well know in the art and will not be described in detail herein. It should be understood, that although the embodiments illustrated herein show the lower most end of the tubular string 2 as having an angular shaped end, the shape should not be viewed as limiting. A variety of other end configurations should be included within the scope of this invention as the end serves to allow easier entry into the seabed B and aid in guiding the tubular string 2 past obstructions as it is lowered from the rig to the seabed B.
[0046] As illustrated in FIG. 19 , an embodiment of the drive-shoe 26 may comprise a miter cut 28 , a solid bottom end 35 , and a hole 34 offset from the longitudinal centerline of the shoe 26 . The solid bottom 35 may be a plug, a cap, a molded cap, a welded end, or other desirable closure member. Preferably, solid bottom 35 will be of an easy drillable, frangible, or otherwise removable material. The hole 34 allows the deflector sub 3 b , and any attached tubulars to pass through as the larger diameter tubular 2 is lowered over the drill string or tubular string 3 . The miter cut 28 preferably permits the conductor pipe 2 to “glance” off and not become hung up on the conductor bay brace 7 ( FIG. 8 ), other tubular strings, or other drilling and production equipment should it come in contact with them. It should be appreciated that when the drive shoe 26 initially contacts the conductor bay brace 7 , other tubular strings, or other drilling and production equipment there will be a point force exerted on the drive shoe 26 from the contact. The hole 34 is preferably provided so that the position of the conductor or tubular string 2 with respect to the drill pipe or tubular string 3 can be controlled. Preferably, the drive-shoe 26 on the conductor pipe or tubular string 2 will effectively “ramp” off the conductor bay brace 7 with little resistance and allow the tubular string 2 to enter the seabed B.
[0047] As further illustrated in FIG. 19 , an embodiment of the drive shoe joint 26 preferably comprises a miter cut 28 with reinforcing material 30 on the long end to prevent curling of the tip 32 . The remainder of the drive shoe is preferably manufactured from steel or another non-drillable material. The miter cut 28 may comprise various angles depending on factors such as, but not limited to, spacing of other guide sleeves 15 ( FIG. 1 ), other drilling strings, casing, tubing, tool joints, tubulars, and other drilling related operations.
[0048] It should be understood that the drive shoe 26 , with the miter cut 28 , may also be utilized to avoid collisions with other tubular strings in a manner similar to the “glancing” effect described herein above. Further, the combination of the drive shoe 26 , with the miter cut 28 , and the guide string 3 , similar to the embodiment illustrated in FIG. 12 , may be utilized to avoid collisions by activating the fluid jet 3 b 1 in conjunction with the miter cut 28 “glancing” operation. It should also be appreciated, that when desired, fluid may also be moved through the bore of the shoe 26 such that the fluid, when exiting through the hole 34 may aid in moving the drive shoe through the softer sediment and mud.
[0049] Operation
[0050] In practicing the present invention, in order to recover the use of an existing slot which has formerly been used in an abandoned wellbore, the existing string or strings of pipe have to first be removed.
[0051] All uncemented strings of pipe, if not stuck within the wellbore, are pulled from the abandoned wellbore, and usually also any pipes remaining between the seabed and the slot to be recovered.
[0052] Any remaining strings of pipe are cut approximately eighty feet below the mudline by conventional apparatus and methods which are well known in the art of cutting tubulars such as casing cutters, production tubing cutters, drill pipe cutters, and the like. Such well-known tubular cutting technology includes the use of mechanical cutters, explosive cutters, chemical cutters, and combinations thereof.
[0053] After the existing strings of pipe have been removed, new strings of pipe are run through the recovered slot and then through the vertically spaced braces such as the guide sleeves 15 used with the braces 1 a - 1 d discussed herein with respect to FIG. 1 . The new string or strings are then run down to or into the mudline and the string or strings can then be moved laterally by the various fluid jetting processes herein described.
[0054] From the foregoing, it will be seen that this invention is one well adapted to attain all of the ends and objects hereinabove set forth, together with other advantages which are obvious and which are inherent to the tubular string deflector and method of the present invention.
[0055] The tubular string deflector and method of the present invention and many of its intended advantages will be understood from the foregoing description. It will be apparent that, although the invention and its advantages have been described in detail, various changes, substitutions, and alterations may be made in the manner, procedure and details thereof without departing from the spirit and scope of the invention. It should be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated by and is within the scope of the claims. | An apparatus for deflecting a tubular string preferably comprising at least one side nozzle near the lower end of a first tubular string. The nozzle permits passage of a fluid therethrough from the first tubular string bore and deflects the first tubular string in a substantially horizontal direction. A second tubular string may be lowered over the deflected first tubular string. The second tubular string and the first tubular string are preferably lowered into the sea floor for maintaining their deflection. A method for deflecting a first tubular string and securing the first tubular string in the deflected state preferably comprises lowering the first tubular string axially so that the lower end of the first tubular string is near the sea floor. Preferably, a fluid, such as seawater, is propelled down through the bore of the first tubular string and through at least one side nozzle near the lower end of the first tubular, wherein the fluid moving through the side nozzle deflects the first tubular string. The first tubular string end is preferably lowered into the sea floor for maintaining the deflection of the first tubular string. A second tubular string may then be slidably lowered over the first tubular string for deflecting the second tubular string. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a device for delivering printed products from a fan arrangement for forming a shingled product stream, the device including an endless chain having a revolving path coordinated with the fan arrangement so that, for forming the shingled printed-product stream, the chain continually slides the printed products out of pockets of the fan arrangement wherein printed products have been received and held by a holding arrangement.
A device of this general type has become known heretofore from the published European Patent Document 0 307 889 B1. A fan arrangement is shown therein having several fan wheels disposed on a common axis in mutually spaced axial relationship. Each fan wheel is formed with fan blades disposed at a predetermined distance from one another and defining pockets therebetween for receiving printed products therein. Between the fan wheels, there is arranged at least one endless chain having angle members and clamping members mounted thereon which are disposed at equal distances from one another. On the one hand, the angle members serve as an abutment or stop for the printed products sliding into a pocket and, on the other hand, serve to slide the printed products out of the pocket in a defined direction and to deposit them on a conveying tape, respectively, so that a shingled printed product stream is formed. Furthermore, the clamping member acts upon the upper side of the printed product and presses it onto the underlying fan blade forming the fan pocket. Because the chain and the fan wheel are axially offset with respect to the fan-wheel axis, the printed product is clamped in a scissors-like manner, receiving a "wavelike" profile.
A disadvantage of this heretofore known device is that the printed product is pressed onto the fan blade, and the friction force created thereby obstructs the sliding movement of the printed product out of the pocket. Furthermore, there is a considerable danger that the underside of the printed product may become smudged.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a device for delivering printed products from a fan arrangement which is gentle to the printed-product material and performs the delivery in a precisely spaced shingled stream of printed products.
With the foregoing and other objects in view, there is provided, in accordance with the invention, a device for delivering printed products from a fan arrangement for forming a shingled printed-product stream, the device including an endless chain having a revolving path coordinated with the fan arrangement, so that the chain continually pushes, out of pockets of the fan arrangement, printed products received in the pockets, for forming the shingled printed-product stream, comprising a holding arrangement for holding the printed products in the pockets, the holding arrangement being formed of grippers disposed on the chain.
In accordance with another feature of the invention, the grippers have a pair of jaws movable towards one another for gripping a respective printed product therebetween.
In accordance with a further feature of the invention, the endless chain comprises a multiplicity of chain links, one of the jaws being formed by a respective one of the chain links, and the device further includes a lever swivelably mounted in the one of the chain links, the other of the jaws being part of the lever.
In accordance with an added feature of the invention, the device includes a spring assigned to the lever for restoring the gripper to an open position thereof.
In accordance with an additional feature of the invention, the device includes a stationary control cam, the lever being formed with a control surface cooperatively engageable with the stationary control cam.
In accordance with yet another feature of the invention, the lever is a double lever, a first arm of the lever forming the other of the jaws, and a second arm of the lever being formed with the control surface.
In accordance with yet a further feature of the invention, the second lever arm is flexible.
In accordance with yet an added feature of the invention, the stationary control cam forms part of a guide path for the chain.
In accordance with yet an additional feature of the invention, the guide path is defined by a U-shaped profile, comprising two legs formed with respective guide grooves for receiving therein respective counterparts on the chain links, and a cross-piece connecting the two legs and forming the stationary control cam.
In accordance with still another feature of the invention, the lever has a swivel shaft, and the counterparts are formed by opposite ends of the swivel shaft.
In accordance with still a further feature of the invention, the chain links are formed, at a longitudinal end thereof whereat the respective chain link is connected to a following chain link, with a nose extending at an inclination to the longitudinal axis of the respective chain link, the nose forming the one of the jaws.
In accordance with a concomitant feature of the invention, the lever has a swivel shaft, and the spring is a torsion spring wound around the swivel shaft, the swivel shaft having respective ends held in the one of the chain links, and the spring being formed with an arm for applying a restoring force to the lever.
The gripper formed on the chain in accordance with the invention offers the advantage that the printed product resting in the fan pocket is subjected only to its own weight. Thus, no additional load or force is exerted on the printed product which could lead to any increased force of impact on the fan blade. This minimizes the counteractive friction force acting on the printed product when it is pushed out of the fan pocket and also protects the underside of the printed product.
The grippers on the chain are preferably formed as jaws moving towards one another for clamping the printed product therebetween, both jaws being located preferably directly opposite one another, so that a scissors-like clamping is avoided.
In a further development of the invention, one jaw is formed by a chain link while the other jaw is part of a lever which is swivelably mounted in the chain link. In this manner the clamping function can be achieved simply by swiveling the lever.
In order to return the lever and therewith the other jaw into an open position, a spring, preferably a torsion spring, is assigned to the lever, the spring being wound around a swivel shaft both ends of which are held in the chain link, an arm of the spring engaging with the lever in a suitable manner.
For the purpose of closing the grippers, the lever is provided preferably with a control surface which comes into contact with a stationary control cam. Thereby, the lever, i.e., the other jaw, is pressed by the control cam against the one jaw formed on the chain link.
The positioning of such a control cam is facilitated by forming the lever as a double lever, with a first lever arm forming the other jaw, and the second lever arm, which preferably projects from the opposite side of the chain link, providing the control surface.
The second lever arm is preferably flexible, so that the printed products are clamped with a force determined by the flexibility of this second lever arm. Furthermore, printed products of varying thickness can be gripped by such a flexible lever arm without any necessity for changing the control cam.
In order to prevent a deflection of the chain in the vicinity of the control cam due to the force applied to the control surface by the control cam, a guide is provided for the chain in the vicinity of the control cam, in accordance with a further development of the invention. This guide is formed preferably of a U-shaped profile, the two legs of which are provided with grooves extending in longitudinal direction, and projections formed on each chain link, preferably the two ends of the swivel shaft of the lever or the two ends of a chain pin, engaging in the grooves. This guide offers the additional advantageous effect that the chain in this region cannot be caused to vibrate, which would otherwise lead to unequal spacings in the shingled product stream.
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 a device for delivering printed products from a fan arrangement, 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, wherein:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a fragmentary, diagrammatic side elevational view of a fan arrangement in the vicinity of a printed-product delivery;
FIG. 2a is an enlarged fragmentary view of FIG. 1 showing an individual chain link of an endless chain conveyor thereof;
FIG. 2b is a perspective view of two jointed chain links of the endless chain conveyor;
FIG. 3 is a fragmentary top plan view of FIG. 2a;
FIG. 4 is an enlarged view of FIG. 2a showing a different embodiment of the chain link according to the invention;
FIG. 5 is a cross-sectional view taken along a plane passing through the conveyor chain and a guide path therefor; and
FIG. 6 is a highly diagrammatic axial view of a fan arrangement according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing and, first, particularly to FIG. 1 thereof, there is shown therein a fan arrangement 1 in the vicinity of the printed-product delivery of a printing press. The fan arrangement 1 includes at least one fan wheel 3, hereinafter also referred to as a fan, which is rotatable by a drive shaft 5 in a direction of rotation indicated by an arrow 7. In the fan wheel 3, pockets 9 are formed which are defined by fan blades 11 in circumferential direction of the fan wheel 3. An inner contour 13 of a fan blade 11 and an opposing outer contour 15 of an adjacent fan blade 11 form an entry funnel which facilitates the entry of a printed product 17 into the respective pocket 9. Due to the arcuate shape of the fan blades 11, the pockets 9 are provided with a profile which causes a slow-down of the printed products 17 as they slide into the respective pockets 9 and before they hit the base 19 of the respective pockets 9. A chain or sprocket wheel 21 driving an endless chain 23 is disposed on the drive shaft 5 and is spaced from the fan wheel 3 in longitudinal direction. The precise configuration of the chain 23 will be described in detail hereinafter.
A repository 25 whereon an overlapping or shingled printed-product stream is deposited, at least in part, is disposed below the fan 3. An end section of the repository 25 initially coming into contact with the printed products 17 has an arcuate shape, in order to keep the spacing thereof from the adjacent fan blade 11 at a minimum. This arcuate section, however, changes into a horizontally extending section meeting at an end thereof, with a conveyor tape or belt 27. On this conveyor tape 27, the printed products 17 are all deposited at defined distances from one another and, as a shingled printed-product stream, are transported in the direction indicated by an associated arrow to a successive processing station.
The chain 23 is guided to the rim of the fan 3 and diagonally downwardly in a direction towards the conveying tape 27 and, in the vicinity of the horizontal section of the repository 25, the chain 23 is guided further by a guide roller 29 into a horizontal plane in parallel with the conveying tape 27. In the further course thereof, the chain 23 is led away from the conveyor tape 27 and back to the chain wheel 21 by a further deflector or guide roller 31.
The chain 23 is formed of individual chain links 33 which are swivelably connected to one another by chain pins 35. A detailed illustration of a chain link 33 is provided in FIG. 2.
Each chain link 33 is formed of a base member 36 formed with a cavity 42, so that side walls 37 are created which are comparable with the side bars or straps of a conventional chain. At a longitudinal end of the base member 36, a projection 39 is formed for receiving a chain pin 35. The length of the chain pin 35 is chosen somewhat greater than the width of the base member 36, so that the chain pin 35 will be able to cooperate with a guide described in detail hereinafter. The chain pin length otherwise corresponds to the width of the base member 36.
A downwardly opening recess 41 is formed in the other longitudinal end of the base member 36, for receiving therein the suitably insertable projection 39 and the chain pin 35 of the succeeding chain link 33. The recess 41 is of such dimensions as to provide a snap-connection.
These chain links 33, which are preferably formed of synthetic material, can be joined in very simple manner, so that the chain 23 used in the fan-wheel arrangement 1 can be easily made longer or shorter.
In the free space 42 formed between the chain pin 35, both side walls 37 and the projection 39, a lever 43 is disposed which is swivelably connected to the side walls 37 by means of a swivel shaft 45. In the interest of clarity the lever 43 is not shown in FIG. 2b.
The lever 43 extends completely through the free space 42 and projects from both sides of the chain link 33. A resetting force is applied to the lever 43 by means of a spring 47, preferably a torsion spring, which biases the lever into a base position thereof represented in phantom in FIG. 2a.
A top plan view of the spring 47 is shown in FIG. 3. In this regard, it is believed to be apparent that the spring 47 is a torsion spring which is wound around the swivel shaft 45 at both sides of the lever 43, both ends 49, respectively, of the thus formed two parallel windings of the torsion spring 47 engaging below a side wall 37, so that these ends 49, when the spring 47 is subjected to tension, can brace themselves against the counter-bearing side wall 37 and cannot escape. Of course, the two ends 49 can also brace themselves at another suitable location, e.g., against a side wall 40 defining the cavity 42, as shown in FIG. 4.
A bracket 51 connecting the two windings of the spring 47 acts upon the lever 43 so as to bias it to return to the base or starting position thereof. On the other hand, this base or starting position of the lever 43 is limited or defined by a stop 53 formed by the end of the projection 39 of the next following chain link 33, as is apparent from FIG. 2a. The spring 47 presses the lever 43 against the stop 53 at an abutment surface 55 of the lever 43 formed specifically for this purpose.
The chain link 33 is provided, at the end thereof formed with the recess 41, with an upwardly projecting nose 57, and a side surface 59 of the nose 57 directed towards the middle of the chain link 33 serves as an abutment or stop for the lever 43, when the lever 43 is moved against the bias of the spring 47. Consequently, due to the interaction or cooperation of the lever 43 and the side surface 59, a gripper device is created, with the side surface 59 serving as a first jaw thereof and the section of the lever 43 facing towards this side surface 59 serving as a second jaw 61 thereof. Between these jaws, a printed product, for example, can then be clamped.
The clamping movement of the lever 43, i.e., a rotation of the lever 43 about the swivel shaft or pin 45 in a clockwise direction, as viewed in FIG. 2a, results in the end 63 of the lever 43 located opposite to the second jaw or end 61 thereof moving or running onto a stationary control cam 65.
The clamping device formed of the two jaws 59 and 61 closes when the lever end 63 serving as a control surface runs onto an initially inclined control cam 65, as represented in phantom in FIG. 2a, in the direction of the arrow during the movement of the chain link 33. Due to the continual reduction of the distance between the swivel shaft 45 and the control cam 65 upon movement of the chain, the lower lever arm with the control surface 63 is pressed backwards opposite to the transport direction of the chain 33 and is consequently turned in a clockwise direction, as viewed in FIG. 2a. The second jaw 61 formed on the other lever arm then approaches the first jaw, that is, the side surface 59 of the nose 57. When the desired end position is reached, the control cam 65 extends farther in parallel with the transport direction of the chain link 33, with a constant clamping force being maintained.
The instant the control surface 63 loses contact with the control cam 65, at the end of the clamping, the lever 43 is returned to the base or starting position thereof by the restoring force of the spring 47.
FIG. 4 shows another embodiment of the lever 43, wherein the chain link 33 as such is identical with the chain link 33 of FIG. 2a described hereinbefore. Thus, those parts of FIGS. 4 and 2a identified by the same reference numerals will not be described again hereinafter.
Contrary to the herein aforedescribed lever 43, the lever 43' shown in FIG. 4 has a lever arm 67 formed with a flexible control surface. By the selection of a suitable material and suitable profiling for this arcuately shaped, flexible lever arm 67, an adjustment and predetermination, respectively, of the pressing force exerted by the jaw 61 against the opposite jaw 59 is permitted.
Thus, the achievement of a uniform clamping force is no longer dependent upon maintaining a precisely defined spacing between the control cam 65 and the swivel shaft or axis 45, as is the case in the exemplary embodiment illustrated in FIG. 2a. The minimum distance between the control cam 65 and swivel axis 45 can consequently be selected to be below a given tolerance range. Printed products of varied thickness can then be clamped without having to change the control surface.
Described in detail hereinafter with respect to FIG. 1 is the interaction or cooperation of the chain 23 and the fan wheel or fan 3.
Initially, for example, a previously folded printed product 17 is delivered into a pocket 9 of the fan 3, the printed product 17 sliding in until reaches the pocket base 19. Then, the edge of the printed product 17 resting on the pocket base 19 butts against the side Of the chain link 33 formed with the nose projection 57. This is accomplished by the rotation of the fan wheel 3 and by the movement of the chain 23 diagonally, i.e., at an inclination, with respect to the rim of the fan wheel 3.
Due to a longitudinal expansion or extension of the individual chain links 33, an expansion which is dependent upon the distance between the individual pockets 9, the printed product 17 comes to lie between the nose projection 57 the lever am 43 having the jaw 61 and being disposed in the base position thereof. Due to a downwardly directed movement of the chain 23 and the rotational movement of the fan wheel 3, the printed product 17 is pushed slowly out of the fan pocket 9 and initially deposited partly on the repository 25. Simultaneously, the clamping function described with respect to FIG. 2a is performed, the control surface of the lever 43 moving onto the control cam 65, and the leading or front edge of the printed product 17 being clamped between the two jaws 59 and 61.
By means of this clamping function, the printed product 17 does not slide out of the fan pocket 9 too fast, which would otherwise lead to an irregularity in the stream of shingled printed products 17.
In the exemplary embodiment illustrated in FIG. 1, the printed product 17 remains clamped between the jaws 59 and 61 even after it leaves the fan pocket 9. The printed product 17 initially supported by the repository 25 is pulled in the direction of the conveyor tape 27 by the chain 23, further transport of the printed product 17 being thereafter assisted by the conveyor tape 27. Only when the printed product 17 is resting completely on the conveyor tape 27 is the clamping released and the printed product 17 accordingly set free. When the speed of the conveyor tape 27 is adapted or matched to the speed of the chain 23, a shingled product stream is formed wherein the spacing of the printed products 17 may be adhered to very precisely.
FIG. 5 shows an exemplary embodiment of a guide for the chain 23, which is provided especially for that section of the chain travel path wherein the clamping of the printed products 17 takes place, i.e., in the vicinity of the control cam 65.
The guide 69 is formed of a U-shaped profile with two legs 71 and a cross-piece 73. The inner side of each leg 71 is formed with a groove 75 extending in transport direction of the chain 23, i.e., in the plane of the drawing of FIG. 5. Respective projections or prolongations of the chain link 33, preferably the two laterally projecting ends of either the swivel shaft 45 or the chain pin 35, engage in the grooves 75.
The inner surface of the cross-piece 73 serves as a control cam 65 which cooperates with the control surface 63 formed on the lever arm 43, as has been explained in connection with the figures described hereinbefore.
The guidance of the chain link 33 in the groove 75 prevents the chain link 33 from deflecting downwardly due to the force applied to the control surface 63 by the control cam 65. Moreover, a slackening and vibrating, respectively, of the chain 23 is effectively prevented thereby.
At the starting end of the control cam 65, the grooves 75, as viewed in circumferential direction of the chain 23, may be opened in a funnel-shaped manner, in order to facilitate the entry of the two ends of the swivel shaft 45 into the grooves 75
FIG. 6 is a diagrammatic illustration of a fan arrangement 1 made up of multiple fans or fan wheels 3 mounted on a drive shaft 5, with chain or sprocket wheels 21 located therebetween, the drive shaft 5, and the chain wheels 21 and the fans 3 therewith being driven, for example, by a belt drive 77.
It is believed to be readily apparent that the invention of the instant application may also be applied to other fan arrangements having only two or three, or more than the four fans shown herein, wherein it may be sufficient to provide only one chain with the grippers. | Device for delivering printed products from a fan arrangement for forming a shingled printed-product stream, the device including an endless chain having a revolving path coordinated with the fan arrangement, so that the chain continually pushes, out of pockets of the fan arrangement, printed products received in the pockets, for forming the shingled printed-product stream, further including a holding arrangement for holding the printed products in the pockets, the holding arrangement being formed of grippers disposed on the chain. | 1 |
BACKGROUND
The MERGE statement is a data manipulation language (DML) statement that may be employed to update a target using data from a source. Each of the target and the source may be a table, for example. Rows in the target that match corresponding rows in the source can be deleted or updated as specified in the MERGE statement. Rows that do not exist in the target can be inserted. Thus, MERGE allows performing a mix of inserts, updates, and deletes in a single statement.
Such a statement introduces new challenges compared to legacy DML statements, where the kind of action to be performed is hard-coded and known at compile time. To effect a MERGE, it must first be determined whether or not a corresponding row exists in the target. If not, then the row from the source may be inserted into the target. If the row exists in the target, then it must be determined whether to update the target row, delete it, or leave it unchanged, based on the source. Sometimes, such queries are nondeterministic, such as where multiple rows in the source correspond to only a single row in the target. Also, the actions to be taken may depend on the order in which the rows are processed.
There is an ongoing desire for more efficient query processing of MERGE statements.
SUMMARY
Disclosed herein are a number of optimizations that provide more efficient processing of MERGE statements. Such optimizations may include: “Halloween Protection” detection for MERGE statements; optimized prevention of non-deterministic MERGE statements; in-place inserts for MERGE statements scanning a “Read Instance” of the target; and optimized execution of MERGE statements seeking the “Read Instance” of the target. Such optimizations may be fundamental in order to ensure proper performance and reliable processing times.
Halloween Protection Detection for MERGE Statements
DML Query Plans are typically divided in two parts—a “read” portion to provide the set of rows to be inserted/updated/deleted, and a “write” portion to apply the changes to the target. Depending on the shape of the query plan, the read and write portion could side-effect each other if not separated through a worktable. This separation is referred to as “Halloween Protection.” In the vast majority of cases, introducing this separation harms performance. Accordingly, to avoid data corruptions and incorrect results, it may be desirable to introduce Halloween Protection in the query plan only when strictly necessary.
A MERGE algorithm as described herein may be employed to detect when Halloween Protection is required, based on the syntax of the command and the actions being performed, the indexes present on the tables involved, and the shape of the query plan. Such an algorithm may ensure that Halloween Protection is introduced only when strictly required.
Optimized Prevention of Non-Deterministic MERGE Statements
A MERGE whose source table is not unique could attempt to modify the same row more than once. This is not permitted because it would likely cause the outcome of the statement to be non deterministic.
A MERGE algorithm as described herein may be employed to detect, at compile time, based on the syntax and actions being performed, and the indexes on the source and target tables, whether the statement could be such to modify the same row twice. When it is detected that the statement could possibly attempt to modify the same row twice, a runtime validation step may be added to the query plan to prevent nondeterministic behavior. The validation may be implemented in a way to minimize the effect on performance.
Statements Scanning the “Read Instance” Of the Target Table
When a MERGE query plan does not contain Halloween Protection, an optimization may be attempted to reuse rows and pages being read from the target instance being joined with the source to qualify the rows to insert. When the source and target are being scanned and joined with a merge join, and a match is not found on the target, the hole may be filled with an insert. The page containing the current outstanding row from the target scan will likely be the same where the row needs to be inserted, because the new row will be inserted right before the currently outstanding row in the leaf level of the B-Tree. If the operation can be done in place on the page, checking the outstanding page can save the B-Tree traversal required to insert the row.
Statements Seeking the “Read Instance” of the Target Table
An optimized application program interface (“API”) may be used to implement MERGE actions (insert, update, delete) with a single B-Tree traversal per affected row. In other words, when such an API is enabled, each action may be performed in the target table with one B-Tree traversal. This may provide an advantage over multi-statement implementations, which, at the very least, need two B-Tree traversals in the worst case scenario. For example, a batch could attempt to update an existing row (one traversal), and if the update did not touch any row then an insert will be made (another traversal).
An optimized API as disclosed herein may tend to improve OLTP-like workloads, for example. Such an API may be enabled by splitting the MERGE Query Execution iterator into two. The first iterator may attempt to insert a row in the target. If the row exists already, then it will be consumed by another MERGE iterator on top to perform an in-place update. In essence, an insertion may be attempted before proving whether the row exists already. For example, if a row already exists, then the already-existing row may be used instead of generating a spurious “unique key violation” error. The optimization may be enabled only when the target table has a unique index.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an example computing environment in which example embodiments and aspects may be implemented.
FIG. 2 is a flowchart of a method for “Halloween Protection” detection for MERGE statements.
FIG. 3 is a flowchart of a method for prevention of non-deterministic MERGE statements.
FIG. 4 is a flowchart of a method for in-place inserts for MERGE statements scanning a “Read Instance” of a target.
FIG. 5 is a flowchart of a method for execution of MERGE statements seeking a “Read Instance” of a target.
DETAILED DESCRIPTION
Exemplary Computing Arrangement
FIG. 1 shows an exemplary computing environment in which example embodiments and aspects may be implemented. The computing system environment 100 is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality. Neither should the computing environment 100 be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary operating environment 100 .
Numerous other general purpose or special purpose computing system environments or configurations may be used. Examples of well known computing systems, environments, and/or configurations that may be suitable for use include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, embedded systems, distributed computing environments that include any of the above systems or devices, and the like.
Computer-executable instructions, such as program modules, being executed by a computer may be used. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Distributed computing environments may be used where tasks are performed by remote processing devices that are linked through a communications network or other data transmission medium. In a distributed computing environment, program modules and other data may be located in both local and remote computer storage media including memory storage devices.
With reference to FIG. 1 , an exemplary system includes a general purpose computing device in the form of a computer 110 . Components of computer 110 may include, but are not limited to, a processing unit 120 , a system memory 130 , and a system bus 121 that couples various system components including the system memory to the processing unit 120 . The processing unit 120 may represent multiple logical processing units such as those supported on a multi-threaded processor. The system bus 121 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. By way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Association (VESA) local bus, and Peripheral Component Interconnect (PCI) bus (also known as Mezzanine bus). The system bus 121 may also be implemented as a point-to-point connection, switching fabric, or the like, among the communicating devices.
Computer 110 typically includes a variety of computer readable media. Computer readable media can be any available media that can be accessed by computer 110 and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media includes both volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CDROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by computer 110 . Communication media typically embodies computer readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of any of the above should also be included within the scope of computer readable media.
The system memory 130 includes computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM) 131 and random access memory (RAM) 132 . A basic input/output system 133 (BIOS), containing the basic routines that help to transfer information between elements within computer 110 , such as during start-up, is typically stored in ROM 131 . RAM 132 typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by processing unit 120 . By way of example, and not limitation, FIG. 1 illustrates operating system 134 , application programs 135 , other program modules 136 , and program data 137 .
The computer 110 may also include other removable/non-removable, volatile/nonvolatile computer storage media. By way of example only, FIG. 1 illustrates a hard disk drive 140 that reads from or writes to non-removable, nonvolatile magnetic media, a magnetic disk drive 151 that reads from or writes to a removable, nonvolatile magnetic disk 152 , and an optical disk drive 155 that reads from or writes to a removable, nonvolatile optical disk 156 , such as a CD ROM or other optical media. Other removable/non-removable, volatile/nonvolatile computer storage media that can be used in the exemplary operating environment include, but are not limited to, magnetic tape cassettes, flash memory cards, digital versatile disks, digital video tape, solid state RAM, solid state ROM, and the like. The hard disk drive 141 is typically connected to the system bus 121 through a non-removable memory interface such as interface 140 , and magnetic disk drive 151 and optical disk drive 155 are typically connected to the system bus 121 by a removable memory interface, such as interface 150 .
The drives and their associated computer storage media discussed above and illustrated in FIG. 1 , provide storage of computer readable instructions, data structures, program modules and other data for the computer 110 . In FIG. 1 , for example, hard disk drive 141 is illustrated as storing operating system 144 , application programs 145 , other program modules 146 , and program data 147 . Note that these components can either be the same as or different from operating system 134 , application programs 135 , other program modules 136 , and program data 137 . Operating system 144 , application programs 145 , other program modules 146 , and program data 147 are given different numbers here to illustrate that, at a minimum, they are different copies. A user may enter commands and information into the computer 20 through input devices such as a keyboard 162 and pointing device 161 , commonly referred to as a mouse, trackball or touch pad. Other input devices (not shown) may include a microphone, joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit 120 through a user input interface 160 that is coupled to the system bus, but may be connected by other interface and bus structures, such as a parallel port, game port or a universal serial bus (USB). A monitor 191 or other type of display device is also connected to the system bus 121 via an interface, such as a video interface 190 . In addition to the monitor, computers may also include other peripheral output devices such as speakers 197 and printer 196 , which may be connected through an output peripheral interface 195 .
The computer 110 may operate in a networked environment using logical connections to one or more remote computers, such as a remote computer 180 . The remote computer 180 may be a personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above relative to the computer 110 , although only a memory storage device 181 has been illustrated in FIG. 1 . The logical connections depicted in FIG. 1 include a local area network (LAN) 171 and a wide area network (WAN) 173 , but may also include other networks. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.
When used in a LAN networking environment, the computer 110 is connected to the LAN 171 through a network interface or adapter 170 . When used in a WAN networking environment, the computer 110 typically includes a modem 172 or other means for establishing communications over the WAN 173 , such as the Internet. The modem 172 , which may be internal or external, may be connected to the system bus 121 via the user input interface 160 , or other appropriate mechanism. In a networked environment, program modules depicted relative to the computer 110 , or portions thereof, may be stored in the remote memory storage device. By way of example, and not limitation, FIG. 1 illustrates remote application programs 185 as residing on memory device 181 . It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers may be used.
Halloween Protection Detection for MERGE Statements
FIG. 2 is a flowchart of a method 200 for “Halloween Protection” detection for MERGE statements. Such a method may be based on the fact that the “read” portion of a MERGE query plan always contains a “join” between the source and the target to qualify the rows to insert, update, or delete. The instance of the target joined with the source may be referred to as the “Read Instance.”
A MERGE statement may be defined as “hole-filling” for a column in the target if: 1) the column is involved in the join predicate between the source and the target, 2) the MERGE statement contains a WHEN NOT MATCHED THEN INSERT clause, and 3) the clause assigns to the column the value to which it is being compared in the join predicate. In other words, the MERGE statement may be defined as “hole-filling” for a column if the INSERT clause exactly populates the value that was found missing in the WHEN NOT MATCHED clause.
If the key or partitioning columns of the index being scanned or sought of the “Read Instance” intersect with the columns being updated in the WHEN MATCHED THEN UPDATE clause of the MERGE statement, then Halloween Protection is required. Otherwise, the update could trigger a movement of the row in the B-Tree such to possibly make the statement process the row twice. MERGE statements are required to process (e.g., insert, update, or delete) the same target row at most once.
At 202 , a determination is made as to whether the target is a heap. As used herein, the term “heap” refers to a table that is not organized as an index, e.g., a table whose rows are stored in no specific order. If, at 202 , it is determined that the target is a heap, then, at 204 , it is determined whether the heap is being scanned as “Read Instance.” If, at 204 , it is determined that the heap is being scanned as Read Instance, then, at 206 , it is determined whether the MERGE statement contains a WHEN NOT MATCHED THEN INSERT clause. If, at 206 , it is determined that the MERGE statement contains a WHEN NOT MATCHED THEN INSERT clause, then, at 208 , it is determined that Halloween Protection is required, because heaps are unordered data structures and newly-inserted rows could be read by the scan. If this were to occur, then the newly-inserted rows could be immediately updated or deleted, generating erroneous results.
At 210 , a determination is made as to whether the source and target are joined with a merge join. If, at 210 , it is determined that the source and target are joined with a merge join, then, at 212 , a determination is made as to whether the MERGE statement is hole-filling for the target merge join keys. If, at 212 , it is determined that the MERGE statement is not hole-filling for the target merge join keys, then, at 208 , it is determined that Halloween Protection is required, because newly inserted rows could be introduced in arbitrary positions of the Read Instance index being scanned.
At 214 , a determination is made as to whether the source and target are joined with a nested loop join. If, at 214 , it is determined that the source and target are joined with a nested loop join, then, at 216 , a determination is made as to whether the MERGE statement is hole-filling for the keys of the Read Instance index being sought that are compared with the source join keys in the seek predicate. If, at 216 , it is determined that the MERGE statement is not hole-filling for the keys of the Read Instance index being sought, then, at 208 , it is determined that Halloween Protection is required, because newly inserted rows could be introduced in arbitrary positions of the “Read Instance” index being sought.
If it is determined that none of the above-described conditions is met, then, at 218 , it is determined that Halloween Protection is not required.
Optimized Prevention of Non-Deterministic MERGE Statements
FIG. 3 is a flowchart of a method 300 for prevention of non-deterministic MERGE statements. A MERGE statement containing either a WHEN MATCHED THEN UPDATE or a WHEN MATCHED THEN DELETE clause could attempt to update or delete the same row more than once if the source does not have a unique index on the join keys. Duplicate join keys from the source could lead to duplicate attempts to update or delete the same matching row in the target. If such a condition is detected during the compilation of the MERGE statement, the query plan will be augmented with appropriate operators that will raise errors preventing multiple attempts to update the same row, and discard duplicate attempts to delete the same row.
According to the method 300 , more than one of the same operation may not be allowed because it could be non-deterministic. At 302 , a determination is made as to whether the MERGE statement contains a WHEN MATCHED THEN DELETE clause. If, at 302 , it is determined that the MERGE statement contains a WHEN MATCHED THEN DELETE clause, then the query plan may be augmented by introducing an operator computing a “Ranking Window Function” before the changes are applied against the target. At 304 , the Ranking Window Function may maintain a counter partitioned by the target keys. The counter may be incremented, at 306 , whenever the action being attempted against the target is a DELETE. At 308 , a filter operator may then be added to the plan, to consume the data stream delivered by the Ranking Window Function computation, and to remove rows with a counter greater than one, i.e., to discard duplicate attempts to delete the same row.
At 310 , a determination is made as to whether the MERGE statement contains a WHEN MATCHED THEN UPDATE clause. If, at 310 , it is determined that the MERGE statement contains a WHEN MATCHED THEN UPDATE clause, the query plan may be further augmented with another Ranking Window Function operator. At 312 , the Ranking Window Function may maintain a counter partitioned by the target keys. The counter may be incremented, at 314 , whenever the action being attempted against the target is an UPDATE or a DELETE. If it is determined, at 316 , that the counter for a given row reaches two, then, at 318 , an error may be raised, because the statement is attempting to update or delete the same row.
In-Place Inserts for MERGE Statements Scanning a “Read Instance” of a Target
FIG. 4 is a flowchart of a method 400 for in-place inserts for MERGE statements scanning a “Read Instance” of a target. When a MERGE query plan does not contain Halloween Protection, an optimization may be attempted to reuse pages being read from the target instance being joined with the source to qualify the rows to insert. When the source and target are being scanned and joined with a merge join, and a match is not found on the target, the hole may be filled with an insert action. The page containing the current outstanding row from the target “Read Instance” index scan may be the same where the row needs to be inserted, because the new row will be inserted right before the currently outstanding row in the leaf level of the B-Tree. Checking the outstanding page can save the B-Tree traversal required to insert the row, if the operation can be done in place on the page.
According to the method 400 , a determination is made, at 402 , as to whether the query plan contains Halloween protection. If, at 402 , it is determined that the query plan does not contain Halloween protection, then, at 404 , it is determined whether the source and target are being scanned with a merge join. If, at 404 , it is determined that the source and target are being scanned with a merge join, then, at 406 , it is determined whether a match is found on the target.
If, at 406 , a match is not found on the target, then, at 408 , the Storage Engine API used to insert a row may be augmented with an optional parameter containing a page reference. At 410 , the augmented API may be invoked with a reference to the currently outstanding page of the target index scan. When such a page reference is present, the Storage Engine may determine, at 412 , whether the page is the one where the new row needs to be inserted. This check is very cheap, because it simply needs to compare the lowest and highest index key column values for the rows currently stored in the page. If the key of the new row to be inserted fits in between, then, at 414 , the insert can be performed directly inside the page, without B-Tree traversals being required.
Optimized Execution of MERGE Statements Seeking a “Read Instance” of a Target Table
FIG. 5 is a flowchart of a method 500 for execution of MERGE statements seeking a “Read Instance” of a target. This optimization applies to query plans where the join between the source and the target is implemented as a nested loop join that seeks an index of the “Read Instance” of the target. The optimization will guarantee that any kind of MERGE action (i.e., insert, update, or delete) requires only a single B-Tree traversal per affected row. In other words, when the optimization is enabled, each action will be performed in the target with one B-Tree traversal.
According to the method 500 , a determination is made, at 502 , as to whether a MERGE query plan is implemented as a nested loop. If, at 502 , it is determined that the MERGE query plan is implemented as a nested loop, then, at 504 , a determination is made as to whether the nested loop join seeks an index of the “Read Instance” of the target. If, at 504 , it is determined that the nested loop join seeks an index of the “Read Instance” of the target, then, at 506 , the MERGE Query Execution iterator may be split into two iterators.
At 508 , the first iterator may attempt to insert a row in the target. The Storage Engine API used to insert a row may be augmented with an optional parameter telling it that, instead of throwing a unique key violation when the row already exists in the target index, the already-existing row should be returned to the caller instead. So, if it is determined, at 510 , that the row already exists in the target, then, at 512 , the already-existing row may be returned to the caller. The caller can then pass the row to the Storage Engine API used to update or delete. Thus, the output of the first MERGE iterator may be consumed by a second MERGE iterator on top to perform an in-place update or delete, at 514 , according to the MERGE statement syntax.
Thus, an insertion maybe attempted before proving whether the row exists already, and, in that case, the already existing row may be used instead of generating a unique key violation error. Because of the algorithm employed, the optimization can only be enabled when the target table index being sought is unique. | Disclosed are systems and methods for optimization and efficient processing of MERGE statements. MERGE allows performing a mix of inserts, updates, and deletes in a single statement, and introduces new challenges compared to legacy DML statements, where the kind of action to be performed is hard-coded and known at compile time. Such optimizations may include Halloween Protection detection for MERGE statements, optimized prevention of non-deterministic MERGE statements, in-place inserts for MERGE statements scanning the “Read Instance” of the target table, and optimized execution of MERGE statements seeking the “Read Instance” of the target table. Such optimizations may be fundamental in order to ensure proper performance and reliable processing times. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a microwave oven having microcomputer incorporated therein and operable according to cooking programs stored in the microcomputer.
2. Description of the Prior Art
Cooking programs are conventionally entered into such microwave ovens incorporating a microcomputer, for example, with use of a cookbook having printed therein photographs and descriptions of various menus and bar code symbols each representing a cooking program for each menu, by tracing the bar code of the desired cooking program with a bar code reader. U.S. Pat. No. 4,323,773 discloses a method of entering cooking programs by bar code reading.
With reference to a large number of photographs contained in the cookbook, a menu which stimulates one's appetite can be selected much more quickly from an extremely wider variety of menus when the bar code symbol printed in the cookbook is thus utilized than when one's imagination is resorted to for selecting a particular menu with reference to the names of menus only. Moreover, the cooking program selected can be entered into the oven very easily without necessitating special skill.
Nevertheless, the conventional method of entering cooking programs into the microwave oven is mainly based on one's appetite excited by viewing photographs, i.e. on sensory selection, so that it is exceedingly troublesome to select a suitable menu with consideration given to the following conditions or requirements attendant on the menu. The chef relies solely on mental work when checking whether the contemplated menu can be cooked within a limited period of time available, whether menus of the same type only are selected frequently or whether the desired caloric value is achievable. For example, when a menu is to be selected from among about ten preselected suitable menus with consideration given to the above conditions, a considerably large number of items of data must be considered, so that there arises the problem that it becomes almost impossible to select an appropriate menu by mental work. Furthermore, when selecting a particular menu, the chef is influenced by her own likes and dislikes likes either consciously or unconsciously. This is likely to make reasonable selection difficult.
SUMMARY OF THE INVENTION
The present invention provides a microwave oven including an oven main body having heating means, and a function unit removably attachable to a front portion of the main body, the function unit having optical reading means for reading cooking data, input means for entering restriction data as to restriction requirements for cooking including heating conditions and cooking time, a memory for storing the cooking data entered by the optical reading means and the restriction data entered by the input means, calculation-control means for comparing and matching the cooking data and restriction data retrieved from the memory and selecting at least one menu fulfilling the restriction requirements from the cooking data, output means for outputting the selected cooking data, and display means for presenting data when the restriction data is entered and output, so that the heating means is controlled according to the selected cooking data when the function unit is attached to the main body.
According to the present invention, the chef first visually preselects, for example, 5 to 10 menus from a cookbook having printed therein photographs and descriptions of various menus and cooking data relating thereto, before selecting the desired menu. Next, the the cooking data as to the 5 to 10 menus preselected from the cookbook is read by the optical reading means included in the function unit, whereupon the data is stored in the memory. The cooker then manipulates the input means while conversing with the display means on the function unit to enter restriction data representing the restriction requirements for cooking, whereby the data is stored in the memory.
The cooking data and the restriction data stored in the memory are retrieved by the calculation-control means and compared for matching, whereby the menus meeting the restriction requirements are selected from the cooking data relating to the 5 to 10 menus and stored in the memory. The selected menus are presented on the display means. The menu to be actually cooked is finally selected from among the selected menus meeting the restriction requirements. The result is stored in the memory. Consequently, even when there are many menus suitable for cooking, the desired-menu fulfilling the conditions contemplated by the chef can be determined quickly and reasonably by a very simple procedure without resorting to the cooking experience or memory of the chef.
Preferably, the input means is so adapted as to set a priority order for the restriction data at the will of the chef. Further preferably, the input means is so adapted as to invalidate the restriction data from item to item in an order reverse to the priority order and to specify the number of data items to be invalidated.
Preferably, the calculation-control means is adapted to cause the display means to show the progress of heating during cooking, when the function unit is attached to the main body.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the appearance of a microwave oven embodying the invention;
FIG. 2 is a front view of a control unit shown in FIG. 1;
FIG. 3 is a perspective view of a function unit cover panel shown in FIG. 2;
FIG. 4 is a side elevation partly in vertical section and showing the control unit of FIG. 2;
FIG. 5 is a fragmentary view of the cover panel of FIG. 4 to show a support portion thereof;
FIG. 6 is a side elevation of an engaging member shown in FIG. 4;
FIG. 7 is a front view showing the function unit of FIG. 4;
FIG. 8 is a fragmentary view of the same as it is seen in the direction of an arrow A in FIG. 7;
FIG. 9 is a block diagram of the function unit;
FIG. 10 (a) and FIG. 10 (b) are flow charts showing the menu selection routine to be executed by the function unit;
FIG. 11 is diagram showing a layout of a cookbook and illustrating the same;
FIG. 12 (a), FIG. 12 (b) and FIG. 12(c) are flow charts showing a process for entering a priority order of restriction requirements and answers into the function unit, diagrams showing the procedure for executing the process, and diagrams showing examples of presentations on a display;
FIG. 13 (a) and FIG. 13 (b) are flow charts showing the steps of changing the priority order and showing the result of retrieval, diagrams showing the procedure therefor, and diagrams showing examples of presentations on the display;
FIG. 14 (a) and FIG. 14 (b) are flow charts showing the steps of entering when to start a dinner and when to start preparation for cooking, diagrams showing the procedure therefor, and diagrams showing examples of presentations on the display;
FIG. 15 (a) and FIG. 15 (b) are the menu retrieval process to be executed by the function unit and diagrams illustrating how to store items of data;
FIG. 16 is a flow chart showing the steps of calculating when to start preparation for cooking, and diagrams illustrating stored data; and
FIG. 17 (a) and FIG. 17 (b) are flow charts showing the process to be executed when the highest priority is given to when to start preparation for cooking, diagrams showing the procedure therefor and diagrams showing examples of presentations on the display.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described below in detail with reference to the illustrated embodiment.
FIG. 1 shows the appearance of a microwave oven embodying the invention and generally comprising an outer case cabinet 1, a control unit 2, a door 3, a tray support 5, a tray 6 and a door opening switch 7. The tray support 5 is adapted to hold the tray 6 thereon and to transmit the rotation of a motor provided on the rear side of the cabinet 1 to the tray 6 to rotate the tray 6, whereby a cooking material placed thereon is uniformly exposed to microwaves.
FIG. 2 is an enlarged front view of the control unit 2. The drawing shows a cooking start switch 9 and a cover panel 10 for a function unit 13.
FIG. 3 is an enlarged perspective view showing the upper portion of the control unit 2. FIG. 4 is a view partly in section and showing the control unit 2. With reference to FIG. 3, the cover panel 10 for the function unit 13 provides a shell for the front upper portion of the control unit 2 and also serves to protect the function unit 13 when the function unit is installed in the control unit 2 as seen in FIG. 4. The panel 10 has a window 11 which is made of a transparent material so that the data fed to a display 30 of the function unit 13 can be read when the function unit 13 is installed in the control unit 2.
With reference to FIG. 4, the function unit 13 is for selecting menus and calculating when to start preparation for cooking as will be described later as the main features of the invention. The oven has a control assembly 14 for controlling the oven in accordance with the heating program to be given by the function unit 13 through a signal transmission channel 15. An engaging member 17 is provided within the control unit 2. As seen in FIG. 6, the engaging member 17 is formed at its top with an engaging portion 19 engageable with an engaging portion 18 of the function unit 13 and has in its front side an engaging portion 21 engageable with the cover panel 10. The signal transmission channel 15 is provided in the engaging member 17 and in the control unit 2 for guiding therethrough signals from the function unit 13 to the control assembly 14. The cover panel 10 is fixed to the control unit 2 by the engagement of a projection 22 at the rear end of the panel upper portion in a recessed portion in the control unit 2. On the other hand, the cover panel 10 is formed at its lower end with a support portion 23 having a slot 25, in which a pin 26 is inserted as seen in FIG. 5, whereby the cover panel 10 is rotatably retained on the unit 2. When the cover panel 10 is rotated through 90 degrees to a horizontal position, the lower extremity of the panel support portion 23 is inserted in the engaging portion 21 of the member 17, whereby the cover panel 10 is fixedly positioned horizontally.
FIG. 7 is a front view of the function unit 13, which generally comprises a main body 29, a display 30 serving as display means, a bar code reader 31 serving as optical reading means, an electronic buzzer 33, a priority order setting switch 34 serving as input means, an answer switch 35 serving as the same, a restriction severity switch 37, a select switch 38, time setting switch H 40 and switch M 41, ENTRY switch 42, CLEAR switch 43, the engaging portion 18 engageable with the engaging member 17 and the signal transmission channel 15.
The display 30 is, for example, a dot matrix liquid crystal display or the like. The priority order setting switch 34 is a seesaw switch of the square type. Depression of a desired portion of the switch 34 selectively enters one of four restriction requirements (category, time restriction, caloric value and experience). The switch 34 also serves to specify the priority order of the restriction requirements which is to be considered in selecting menus. A priority order is set in the order in which the restriction requirements are selected by depressing the switch 34. Like the switch 34, the answer switch 35 is a seesaw switch of the square type. The switch 35 selectively enters an answer specifying one of the selection numbers for a restriction requirement shown on the display 30 when the requirement is entered. The restriction severity switch 37 is a step switch of the seesaw type. Many different items of data can be entered by pushing the switch 37 at a selected portion a selected number of times. As to the four kinds of restriction requirements entered by the priority order setting switch 34, the severity switch 37 determines the number of requirements, as counted from the one selected first in a descending order of priority, to be fulfilled.
The select switch 38 is a seesaw type step switch. When a plurality of menus meeting the selected restriction requirements are selected from among the items of cooking data entered by the bar code reader 31, the select switch 38 gives an instruction to present the names of the selected menus one by one on the display 30 as will be described later. The time setting switches H 40 and M 41 are each a seesaw type switch and are used for entering the dinner start time desired by the user. The switch H 40 is an "hour" setting switch which is adapted to set the hour in one-hour units every time it is depressed once. The switch M 41 is a "minute" setting switch for setting time in 10-minute unit every time it is depressed once. To alter the time setting easily, each of the switches 40 and 41 is so adapted that when one of the illustrated portions, i.e. "+" side or "-" side, thereof is depressed, the setting can be altered by addition or subtraction.
ENTRY switch 42, when manipulated, gives one of the following execution instructions (1) to (3) in the step concerned of the operation of the function unit 13 to be described.
(1) Instruction to specify the menu to be finally selected from among the menus suitable for cooking and presented on the display 30.
(2) Instruction to calculate when to start preparation for cooking the desired menu.
(3) Instruction to transfer to the control assembly 14 of the microwave oven the heating program included in the cooking data which is read by the bar code reader 31 and which relates to the finally selected menu (after the function unit 13 has been installed in the control unit 2). Subsequently, the switch automatically serves to newly register the number of times (frequency) the heating program for the finally selected menu is used, in a specified area in the memory to be described later or to renew such data.
CLEAR switch 43, when manipulated, gives one of the following execution instructions (1) and (2).
(1) Instruction to erase the cooking data relating to menus and entered upon reading by the bar code reader 31.
(2) Instruction to ease the restriction requirement priority order and answers entered by the setting switch 34 and the answer switch 35, respectively.
The instruction (1) is executed by depressing CLEAR switch 43 once, and the instruction (2) by pushing the switch 43 twice in succession.
The function unit 13 is connected to the control assembly 14 by the signal transmission channel 15 when the engaging portion 18 of the function unit 13 is engaged with the engaging portion 19 of the engaging member 17 in the control unit 2. A signal transmitted from the function unit 13 and representing the heating program for the oven is fed to the control assembly 14 in the control unit 2 through the signal transmission channel 15.
When removed from the control unit 2 after opening the cover panel 10, the function unit 13 serves as an independent unit, while when attached to the control unit 2, the function unit 13 serves as input-output means for the control assembly 14. Preferably, therefore, the function unit 13 is provided in a front portion of the microwave oven main body.
FIG. 8 is a fragmentary view of the function unit 13 as it is seen in the direction of arrow A in FIG. 7. The time setting switch M 41, a seesaw switch, is embedded in the main body 29 of the unit 13. An actuating projection 41a or 41b on the switch 41, when depressed, selects the mode to be specified by the switch 41.
FIG. 9 is a block diagram showing the function unit 13 as divided into the input means, control means, memory means and output means, which are shown as arranged from left to right.
The input means serves to enter the conditions desired by the user and comprises the following means (a) to (f).
(a) Input means (bar code reader 31) for the cooking data as to the menus to be selected.
(b) Input means for restriction requirements (priority order setting switch 34, answer switch 35, restriction severity switch 37).
(c) Means for changing the data to be given to the display 30 (select switch 38).
(d) Means for entering dinner start time for calculating when to start preparation for cooking (time setting switches H 40 and M 41).
(e) Means for entering an instruction to load a heating program for the finally selected menu onto the control assembly 14 (ENTRY switch 42).
(f) Means for clearing input data (CLEAR switch 43).
The control means, which controls the operation of the function unit 13, includes a microcomputer having a ROM (read-only memory) 46, a CPU 45 serving as calculation-control means for controlling the function unit 13 according to a system program already stored in the ROM 46, and an input-output interface 47 connected to the CPU 45, the ROM 46, the above-mentioned input means and the memory means to be described below and also connected to the output means to be described below via a driver 50.
The memory means stores the data needed for the operation of the function unit 13 and includes the following memories: a RAM (random access memory) 49 having data areas [1] and [2] for storing therein cooking data as to menus from which suitable menus are selected and a data area [4] for storing the restriction data therein, a RAM 51 having a data area [3] for storing therein the number of times the heating program for each menu was used in the past, and a ROM 53 for use in storing the data needed when the function unit 13 serves as a monitor display for showing the heating state of the oven.
The output means includes the display 30 and the electronic buzzer 33. The display 30 gives instructions on input procedures and presents input results and output results. The buzzer 33 gives notice to the arrival of the time to start preparation for cooking.
To sum up, the function unit 13 with the foregoing construction has the following functions.
I. As a separate function unit:
(1) The function of entering menu cooking data by the bar code reader 31.
(2) The function of entering the desired priority order of restriction requirements for cooking and answers as to the restriction requirements.
(3) The function of retrieving menus meeting the specified restriction requirements.
(4) The function of calculating when to start preparation for cooking with cooking experience considered.
II. As input-output means for the control assembly 14 (when attached to the control unit 2):
(1) The function of loading heating programs onto the control assembly 14.
(2) The function of presenting progress of heating by the oven on the display 30.
The operation of the microwave oven having the construction described above will be described with reference to the flow charts of FIG. 10(a) and FIG. 10(b).
In step S1, the function unit 13 is removed from the control unit 2, and the cooking data for to 5 to 10 menus selected with reference to photographs in the cookbook is read by the bar code reader 31 and stored in the RAM 49 (pre-selection).
Step S2 enters the priority order of restriction requirements desired by the chef and answers to inquiries as to the restriction requirements.
In step S3, the CPU 45 retrieves the menus meeting the restriction requirements from the cooking data for the 5 to 10 menus entered (final selection).
In step S4, the CPU 45 inquires whether the restriction requirement meeting menus are present. When the answer is affirmative, step S7 follows, or if otherwise, step S5 follows.
In step S5, the CPU 45 presents a message requesting relaxed restriction requirements on the display 30 since no menu is available to satisfy the requirements.
In conformity with the request made in step S5, the chef reduces the severity of requirements in step S6, followed by step S3.
In step S7, the names of the plurality of menus fulfilling the restriction requirements are presented on the display 30 in succession along with the page numbers of the cookbook concerned.
In step S8, the menu desired by the chef, if found, is specified by ENTRY key 42, followed by step S10. If otherwise, the sequence proceeds to step S9.
When the cooker desires to change the priority order in step S9, step S2 follows again. If retrieval is to be resumed in the priority order already specified, the sequence returns to step S1.
In step S10, the chef enters a scheduled dinner start time.
In step S11, the CPU 45 calculates when to start preparation for cooking the menu finally determined in step S8, based on the scheduled dinner time entered in step S10. The result is shown on the display 30.
In step S12, the chef checks whether the menu can be cooked. If the result is affirmative, step S13 follows, or otherwise, the sequence returns to step S1 to reselect menus.
In step S13, the function unit 13 is installed in the control unit 2 on the oven, and the heating program included in the cooking data stored in the RAM 49 in step S1 is loaded into the control assembly 14, whereby the present process is completed.
Next, the above operation will be described in greater detail as the following procedures (1) to (4). (1) Entering cooking data by bar code reader 31 (FIG. 10(a) step S1)
FIG. 11 is a diagram showing a layout of the cookbook 54 prepared for the above microwave oven as an embodiment of the invention. The cookbook 54 has printed therein a photograph 55, description of cooking method 57, cooking time 61 and caloric value 62 as visible data, as commonly contained in conventional cookbooks. In addition to the above visible data, the cooking data for use in selecting the menu shown is printed in the form of a bar code symbol 59. The cooking data includes PG,20 a code P6 for a cooking mode (heating method for the menu) symbol 58, total cooking time P4 (heating time P4a+standard preparation time P4b) and caloric value P5. The bar code symbol 59, which is provided to greatly facilitate the primary selection of the menu by the chef, includes the above cooking data (P4, p4a, P4b, P5, P6) for use in selecting the menu, and further the menu name P1, heating program P2 (inclusive of a signal relating to displaying) and page number P3 concerned in the cookbook 54 which are necessary for the CPU 45 to inform the chef of the selected menu. The code P6 representing the cooking mode symbol 58 is used for the CPU 54 to access a table of cooking mode symbols 58 prepared in the ROM 46 to present the corresponding symbol 58 on the display 30.
The bar code symbol 59 printed in the cookbook 54 is read by holding the function unit 13 as removed from the control unit 2 and tracing the symbol 59 with the bar code reader 31 on the unit 13 in contact therewith. Accordingly, the chef can enter the cooking data easily with reference to the visual data such as the photograph 55 without necessitating special training or the like. The cooking data as to each of the selected menus entered by the code reader 31 in this way is stored in the data area [1] of the RAM 49.
(2) Setting restriction requirements for cooking (FIG. 10(a) step S2)
The menus stored in the RAM 49 of the function unit 13 with reference to the photographs 55 showing the menus as finished, etc. in the cookbook 54 are selected based solely on the appetite of the chef. Accordingly, these menus have not been checked as to problems which are usually checked based on the memory of the chef resulting from her experience, e.g., whether the menu can be cooked on week days when a sufficient period of cooking time is not available to two-income families, whether the menu appears fresh to taste and what menu has a satisfactory caloric value in view of the health of the family. Further in examining these problems, it is important to note that the priority order of these items differ from chef to chef, and that even with the same chef, the priority order changes with a change in the living condition. In view of the above situation, the category of menu (heating method), time restriction, caloric value and experience are set as the items of restriction requirements to be checked, and the input means is given the function of setting these requirements in a priority order according to the present invention. Furthermore, the input means is adapted to re-set the minimum essential requirements to be fulfilled when no menu is available to satisfy all the restriction requirements specified so as to permit flexible selection.
How to set restriction requirements for cooking in the desired priority order and how to enter answers as to these requirements will be described below with reference to the flow charts of FIG. 12 (a)-FIG. 12 (c). FIG. 12 (a)-FIG. 12 (c) also show a procedure for entering data into the function unit 13, presentations on the display 30 of the unit 13 during this procedure. In FIG. 10 and FIGS. 12 (a)-(c), like steps are referred to by like step numbers. When a series of steps in FIGS. 12 (a)-(c) show the details of a particular step in FIG. 10, the steps of the series are designated by attaching consecutive adscript numbers to the reference numeral of the corresponding step in FIG. 10, for example, by S21, S22, S23, . . . corresponding to S2.
In FIGS. 12 (a)-(c), the following priority order is given as an example to the above four kinds of restriction requirements.
(1) Category of menu
(2) Cooking time restriction
(3) Cooking experience
(4) Caloric value restriction
The above priority order is set by entering in this order the four portions, i.e. category, time restriction, experience and cal. value sections, of the priority order setting switch 34 which is a square-type seesaw switch as already mentioned.
More specifically stated, the category section of the switch 34 is pushed in step S21 as shown in procedure step O1, whereupon the dispaly 30 presents the cooking mode symbols 58 representing different categories and numbers one of which is to be selected as an answer as shown in display step D1.
In step S22, the chef answers with one of the selection numbers shown in display step D1 by depressing, for example, the section "2" of the answer switch 35 which is a square-type seesaw switch, as seen in procedure step O2.
When step S23 finds that all restriction requirements have not been specified, the sequence returns to step S21.
In step S21, another restriction requirement and an answer are entered. More specifically, "time restriction" in the second place of the priority order is specified by pushing the corresponding section of the switch 34 in procedure step O3, whereupon selection numbers are presented as shown in display step D2.
In step S22, the selection number corresponding to the time available is specified by pushing, for example, the section "1" of the answer switch 35 again, whereby the second requirement is completely entered.
Steps S23 to S21 are thereafter repeated until all the restriction requirements are specified. In procedure steps O5 and O7, the priority order setting switch 34 is manipulated to set the remaining restriction requirements in the desired priority order. With reference to the selection numbers shown in display steps D3, D4, the answer switch 35 is manipulated in procedure steps O6, O8, respectively, to enter one of the numbers as an answer each time.
Upon step S23 detecting that all the restriction requirements have been specified, the sequence proceeds to step S3 in FIG. 10.
The above inputs (priority order of restriction requirements and answers as to the requirements) are stored in the data area [4] in the RAM 49.
(3) Retrieving and displaying menus meeting restriction
requirements (FIG. 10, steps S3 to S8)
FIG. 13(a) and FIG. 13(b) show flow charts, examples of presentation on the display and a procedure.
In step S3, the CPU 45 compares the inputs of the restriction requirements with the cooking data as to the individual menus entered through the bar code reader 31 for matching to retrieve menus meeting the requirements, followed by step S4.
Step S4 inquires whether there are menus meeting the requirements. If the answer to the inquiry is in the affirmative, step S65 follows, or if otherwise, step S5 follows.
In step S5, the display 30 presents the message, "Your Menu Not Found. Relax Your Requirements" as shown in display step D5, whereupon the sequence proceeds to step S61.
In step S61, a message is given instructing the chef to reduce the requirement severity as shown in display step D6. More specifically, the display 30 presents the message, "Locate ∇ to Your Taste," meaning that a requirement severity indicating symbol "∇" is to be shifted, along with 4/4, 3/4, 2/4, 1/4 each indicating a minimum number of essential requirements to be fulfilled relative to the total number of requirements. These numerical symbols are used for specifying the number of requirements to be adopted at the higher places in the priority order of the four requirements set in steps S21 to S23 in FIG. 12 to abandon the remaining requirement(s) at the lower place(s). In step S61, therefore, the restriction severity switch 37 is depressed as shown in procedure step O9. This switch 37 has two portions to be pushed. Depression of a projection on the "high (H)" side shifts the symbol "∇" leftward to increase the restriction severity, whereas depression of a projection on the "low (L)" side shifts the symbol rightward to lower the severity. Every push varies the restriction severity by an amount corresponding to one requirement. In the case of FIG. 13 (a), for example, the "L" projection (for decreasing the restriction severity) is depressed once to shift the symbol "∇" one step rightward as shown in display step D7. Consequently, the effective restriction requirements are the three of:
(1) Category of menu
(2) Cooking time restriction
(3) Cooking experience
The requirement "caloric value" is thus abandoned.
When required, the severity switch 37 is further depressed a required number of times in step S62 to reduce the number of restriction requirements.
In step S63, the CPU 45 retrieves menus again at the reduced restriction severity.
Step S64 checks whether suitable menus meeting the requirements are available. If the answer is negative, the sequence returns to step S5 to give a warning message again. When the answer is affirmative, the sequence proceeds to step S65. FIG. 13 (b) shows that a plurality of menus are selected which meet a reduced number of, i.e. three, restriction requirements.
The retrieval of the plurality of menus in step S65 is followed by step S71, whereas if a single menu is retrieved, step S73 follows.
In step S71, the display 30 shows the name of the first menu, the number of the cookbook page giving the menu, the symbol "→" and a guide message as shown in display step D8.
In response to the above message, the select switch 38 of the seesaw type is depressed on a projection at its "+" side as indicated in procedure step O10, whereby the plurality of menus meeting the restriction requirements are presented on the display 30 one after another in the increasing order of address numbers on the memory storing these menus. Every push of the switch 38 displays one menu.
Upon step S72 detecting that the menu to be displayed is the last of the plurality of retrieved menus, the sequence proceeds to step S73.
When step S73 displays the last menu, i.e. the menu stored with the largest address number in the memory, the display 30 presents only the name of the menu and the page number concerned of the cookbook 54 as shown in display step D9. Furtherwhen it is desired to recheck the menus already presented on the display 30, a projection on the "-" side of the select switch 38 is depressed. In this case, the menus are shown on the display 30 in the decreasing order of address numbers, one menu for every push of the switch.
When the desired one of the retrieved menus is presented on the display 30, ENTRY switch 42 is depressed in step S8, whereby the menu to be cooked is specified.
When the restriction requirements are to be changed because the desired menu is not obtained eventually, CLEAR switch 43 is depressed. This erases the cooking data entered by the bar code reader 31 and stored in the RAM 49 and also the restriction data entered by the priority order setting switch 34 and the answer switch 35 and stored in the RAM 49.
(4) Calculating when to start preparation for cooking
(FIG. 10(b), steps S10 and S11)
After the menu meeting the requirements set by the chef has been finally selected from among the plurality of menus preselected from the visual data in the cookbook 54 as described above, the time to start preparation for cooking is calculated so that the menu can be completely cooked in time for starting the dinner at the desired time. This process will be described with reference to the flow charts of FIGS. 14(a), 14(b). FIGS. 14(a), 14(b) also show the procedure for this process, exemplary presentations being shown on the display 30.
In steps S101 and S102, the chef depresses the time setting switch H 40, a seesaw switch, to set the "hour" of the desired dinner time as shown in procedure step P12, whereupon the time setting (hour only) is displayed as seen in display step D10.
The switch H 40 is an "hour" setting switch, while the time setting switch M 41 is a "minute" setting switch. One push of the "+" side projection of each of these switches 40, 41 advances the switch H 40 by one hour or the switch M 41 by 10 minutes. On the other hand, one push of the "-" side decreases the time setting by a decrement of the same time unit as above for correcting the advanced time setting.
In steps S103 and S104, the time setting switch M 41 is depressed to set the "minute" as shown in procedure step O13, whereupon the time setting is displayed as seen in display step D11.
After the scheduled dinner time has been set, ENTRY switch 42 is depressed in step S105, commanding the system to calculate when to start preparation for cooking the selected menu.
In step S111, the total cooking time P4 (heating time P4a+preparation time α·P4b) is read out from the data area [2] of the RAM 49, as corrected by the method to be described below in detail.
In step S112, the cooling preparation start time is calculated by subtracting the total cooking time P4 from the dinner start time already set as above.
In step S113, the preparation start time is presented on the display 30 as shown in display step D12.
Subsequently, the function unit 13 is installed in the control unit 2 in engagement with the engaging member 17 and thereby connected to the control assembly 14. ENTRY switch 42 is then depressed, whereby the heating program for the menu to be cooked is transferred to the control assembly 14.
Upon the step S14 detecting that the calculated preparation start time has arrived, step S15 follows, presenting a warning message on the display 30 as shown in display step D13 and turning on the electronic buzzer 33 provided on the main body 29 of the function unit 13 to give an alarm. The system now waits for an instruction to start cooking.
The cooking data as to the preselected suitable menus entered into the function unit 13 by the bar code reader 31 is compared with the restriction requirement data entered by the priority order setting switch 34 and the answer switch 35 for matching by the method to be described below with reference to the flow charts of FIGS. 15(a), 15(b).
In step A21, the cooking data for the suitable menus is entered by the bar code reader 31 in terms of bar code symbols 59 (see FIG. 15 (a)).
The cooking data input is stored in the data area [1] of the RAM 49 in step A22. In the data area [1], a high address (100, 200, . . . ) is assigned to the data as to one menu. The individual items (the items P1 to P6 included in the symbol 59) constituting the data as to one menu are stored at respective small addresses (10, 20, . . . ) constituting the high address. This can be realized by the function of the CPU 45 to renew the high address to be used for storing every time it starts reading the symbol 59 for a new menu and by the function thereof to renew the small address for storing every time it reads a data segment code symbol 63 provided in the bar code symbol 59 for each data item therein.
In step A23, the desired priority order of the four restriction requirements is entered by manipulating the switch 34 as already described.
Step A24 specifies the order in which the items of data are to be registered at their respective specific addresses in the data area [4] of the RAM 49, in conformity with the priority order entered in step A23. Data area [4] shows that the specified order is the same priority order as in the procedure of FIGS. 12(a)-12(c). Next, each answer of the user is registered at the specified address upon the depression of the answer switch 35. On completion of the above requirement input procedure, the sequence proceeds to step A25.
Of the individual items (P1 to P6) of the menu cooking data stored in the data area [1] of the RAM 49, those relating to the selection of menu (total cooking time P4, caloric value P5 and cooking mode symbol P6) are rearranged in the requirement input order and stored in the data area [2] for each menu in step A25. Since the "experience" data at the third place of the priority order has not been stored in the data area [1] at this time, a small address 60 is secured in the data area [2] for storing this data therein later.
In step A26, data is retrieved as to,the frequency of cooking of each menu (experience). The cooking frequency of each menu is stored in the data area [3] of the RAM 51. As already stated, this data is automatically registered or renewed when the heating program concerned is loaded into the control assembly 14 by ENTRY switch 42, with the function unit 13 installed in the control unit 2. All menus (M1 to M5 in the case of FIG. 15(b)) registered in the data area [3] of the RAM 51 are checked as to their cooking record, and the cooking frequency data as to those already cooked in the past is registered at the specified location of the data area [2] of the RAM 49, i.e. at the small address 60 secured as above.
Of the menu cooking data entered by the bar code system, the items of data relating to menu selection are re-registered by the above process in the same order as the priority order of restriction requirements set by the chef.
In step A27, the restriction requirement data entered is matched with the data relating to menu selection for each menu.
Next, a description will be given of the abovementioned method of correcting the total cooking time P4 for use in calculating when to start preparation for cooking. As shown in FIG. 11 and FIGS. 15(a), 15(b), the total cooking time includes "heating time" and "standard preparation time" which are included in the print of bar code symbol 59 for each menu as P4a and P4b, respectively. The numerical value data items of the heating time and the standard preparation time read by the reader 31 are respectively stored at small addresses 40 and 50 in the data area [1] of the RAM 49 in the function unit 13 as seen in FIG. 15 (a).
With reference to the flow chart of FIG. 16, step S31 reads out the cooking frequency Cn of the first of the menus stored in the data area [3] of the RAM 51. In this step, the cooking frequency Cn of the menu not stored in the data area [3] is construed as 0.
For the menu read out in step S31, a correction parameter α for the preparation time relative to the cooking frequency Cn is read out from the data area [5] of ROM 46 in step S32.
In step S33, the "standard preparation time" P4b registered in the data area [1] of the RAM 49 is multiplied by the correction parameter α read out to obtain corrected "preparation time" α·P4b. To the corrected "preparation time" α·P4b is then added the "heating time" P4a to calculate the total cooking time P4, which is thereafter stored at the pertinent small address 50 in the data area [2] of the RAM 49. Subsequently, the time to start preparation for cooking is calculated from the scheduled dinner start time entered as already stated (FIG. 14) and the total cooking time P4 corrected as described above.
When the desired menu is to be selected with the highest priority given to dinner start time other than the foregoing four restriction requirements, the restriction requirements other than time restriction are entered for the retrieval of suitable menus, and the dinner start time is then set to determine the desired menu. This process will be described with reference to the flow charts of FIG. 17(a) and FIG. 17(b) show the procedure. FIGS. 17(a), 17(b) showing examples of presentations on the display 30. In setting the restriction requirements, the time restriction requirement is set at the fourth place of the priority order. Next, the restriction severity is set to "3/4" to exclude the time restriction requirement from the items to be compared for matching. Subsequently, a plurality of suitable menus are selected which fulfill the three restriction requirements. These suitable menus are then checked as to the time to start preparation for cooking, as will be described below.
In step S41, the name of one of the suitable menus, the page number concerned of the cookbook 54 and a guide message are presented on the display 30 as seen in display step D21.
When the cooker finds it necessary to check the displayed menu for the preparation start time in step S42, ENTRY switch 42 is depressed in step S43 (procedure step O21).
When it is found in step S44 that the chef has not checked all the suitable menus, the select switch 38 is depressed in step S45 (procedure step O22) to display the next menu. Steps S41 to S45 are repeated to completely check all the suitable menus, whereupon the sequence proceeds to step S46.
In step S46, the desired dinner start time is set in the same manner as already described (procedure step O23), whereupon the time setting is shown as seen in display step D22.
Depression of ENTRY switch 42 in step S47 (procedure step O24) is followed by step S48 to calculate when to start preparation for cooking the menu specified in step S43, in the manner already described.
In step S49, the display 30 shows the name of the first menu for which the preparation start time is calculated as above, the preparation start time and the page number concerned of the cookbook 54 as shown in display step D23.
In step S50, the select switch 38 is manipulated as already stated (procedure step O25). Thus, all the menus specified in step S43 are checked on the display 30 as to the preparation start time.
When the menu desirable to the cooker is found in step S51, ENTRY switch 42 is pushed in step S52 (procedure step O26) to eventually specify the desired menu.
The operation software of the foregoing embodiment may be replaced by other operation software insofar as it is possible for the chef to invalidate one or more restriction requirements of lower priority to select menus fulfilling the restriction requirements of higher priority when menus satisfying all the restriction requirements initially set by the chef are not available.
With the microwave oven of the invention described above, the desired menu fulfilling the restriction requirements contemplated by the chef can be selected by a simple procedure without necessitating any special skill or without entailing the burden that the chef must resort to the memory of cooking experience in the past. The function unit, which is removable from the oven main body, permits the user to select menus and enter cooking data at any desired place irrespective of the location of the oven.
Furthermore, the input means is so adapted that the desired priority order issettable by the chef at her will. When the input means is provided with means for specifying the number of restriction data items to be used in the priority order thus set and invalidating restriction data from item to item in an order reverse to the priority order, the priority order of restriction requirements can be changed with flexibility, for example, in conformity with a change in the environmental conditions of the chef.
The calculation-control means calculates when to start preparation for cooking, as corrected in accordance with the cooking frequency experienced, relative to the dinner start time and is provided with means for giving a signal indicating the preparation start time upon the arrival of the start time. Accordingly, by merely specifying the desired dinner time by a simple procedure, the cooker can start preparation for cooking without forgetting so as to be in time for the scheduled dinner time even if the time available for cooking is greatly limited. | A microwave oven including an oven main body having a heater, and a function unit removably attachable to a front portion of the main body is provided. The function unit includes an optical reader for reading cooking data, an input device for entering restriction data as to restriction requirements for cooking, a memory for storing the cooking data entered by the reader and the restriction data entered by the input device, a calculator-controller for comparing and matching the cooking data and restriction data retrieved from the memory and selecting at least one menu fulfilling the restriction requirements from the cooking data, a device for operating the heater according to the selected cooking data when the function unit is attached to the main body, and a display for presenting data when the restriction data is entered and output. By a simple procedure, the desired menu is selectable which satisfies various cooking restriction requirements contemplated by the chef. The function unit permits the chef to select menus and enter cooking data at a desired place away from the main oven body. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an opto-electronic scale reading apparatus used to measure displacement of one member relative to another.
2. Description of Related Art
One such type of a apparatus is known from GB 1,504,691 which discloses a readhead which is movable relative to a reflective scale, and which illuminates the scale with light via an index grating (the light being substantially perpendicular to the scale), to generate a periodic light pattern in the plane of the said index grating. The index grating thus serves as an analyser grating, and relative movement between the scale and the readhead results in a light modulation at the analyser grating. Also disclosed in this document is the generation of moire fringes by skewing the lines of the index grating fractionally with the respect to the direction of the lines of the scale. Such an arrangement is susceptible to differential contamination of the scale (the propensity of different regions of the scale to interact in a different way with a given beam of incident light), and so is inherently inaccurate.
To overcome this problem it has been proposed to provide an auxiliary grating, or other beam splitting means, up-beam of the analyser grating in order to generate plurality of phase-shifted light intensity modulations at the analyser grating. Such an arrangement is described for example in our co-pending international application WO 89/05440. However, such an arrangement is unsuitable for the situation in which the readhead is movable over a large distance (i.e. greater than 10 mm) relative to the scale in a direction perpendicular to the plane of the scale since, in the above described arrangement, the light is incident upon, and reflected off the scale at an angle. Movement of the readhead relative to the scale perpendicular to the plane of the scale changes the angle of incidence of the light on the scale detected by a detector, and thus requires a re-adjustment of, for example, the optics used to focus light onto relevant photo-detectors.
SUMMARY OF THE INVENTION
A first aspect of the present invention lies in the appreciation of the problem of providing a readhead of the type generally discussed above, in which light is incident upon a reflective scale in a direction substantially perpendicular to the scale plane, and in which a plurality of phase-shifted signals are generated from one or more light intensity modulations at an analyser which are not subject to differential contamination of the scale.
According to the present invention there is provided opto-electronic scale reading apparatus comprising a reflective scale defined by a series or spaced-apart lines, and a readhead movable relative to the scale in the direction of spacing of the lines, the readhead comprising: an index grating; an analyser, the index grating and analyser occupying spatially distinct positions; a light source for illuminating the scale via the index grating, thereby to generate a periodic light pattern in the plane of the analyser, and a modulation of light intensity upon relative movement of the scale and readhead; means for generating from said intensity modulation a plurality of phase-shifted electrical signals, each signal having a frequency corresponding to the frequency of said modulation;
wherein:
means are provided for directing the light
a) along a first path from the index grating to an intersection point;
b) from the intersection point, to the scale and back to the intersection point along a common path in a direction substantially perpendicular to the scale; and
c) from the intersection point to the analyser, along a second path.
Preferably, such an arrangement will be achieved by providing for example a beam splitter cube, in the path of the light passing through the index and/or the light reflected off the scale.
Preferably the phase-shifted light modulations will be generated at the analyser by any suitable method which avoids differential contamination. For example, beam splitting means may be provided for splitting the periodic light pattern at the surface of the analyser into a plurality of such patterns.
An embodiment of the present invention will now be described, by way of example, and with reference to the accompanying drawings in which:
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a schematic illustration of a scale and readhead according to the present invention; and
FIG. 2 shows a practical example of a 3-D transducer system incorporating a scale and readhead according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIG. 1, a scale 10 extends in a plane defined as the XY plane and has markings 14 which extend parallel to the X direction and are spaced in the Y direction. A readhead 16 is movable relative to the scale in the X,Y and Z directions. The purpose of the readhead however is merely to measure displacement relative to a datum in the Y direction. The readhead 16 comprises a diffuse light source 20 provided adjacent an index grating 22, which has lines extending parallel to the X direction, spaced in the Z direction, and extending in the XZ plane. The beam of light generated by the light source 20 passes through the index grating 22 travelling substantially in the Y direction and is then incident upon a semi-silvered mirror 24 of a beam splitter cube 26. The mirror 24 directs the light beam through 90°, and onto the scale 10 in a direction perpendicular to the plane of the scale. Light reflected off the scale 10 travels back along its path perpendicular to the plane of the scale 10, through the beam splitter cube 26. A periodic light pattern, formed by the interaction of the light passing through the index grating 22 with the scale 10 is generated in the plane of an analyser grating 28; the analyser grating 28 has lines extending in the X direction, spaced in the Y direction, and the grating 28 extends in the XY plane substantially parallel to the scale 10. Relative movement of the readhead and the scale 10 in the Y direction results in the periodic light pattern generated in the plane of the analyser grating 28 moving relative to the analyser grating 28, thereby producing a modulation of light intensity indicative of the relative movement between the readhead and scale 10, which is detected by a photo-detector array 40.
In order to determine the direction (i.e. +Y or -Y) of relative movement of the scale and readhead a plurality of phase-shifted light modulations are generated at the analyser grating 28 by an auxiliary grating 36. The auxiliary grating 36 extends in the XY plane, and has lines extending substantially parallel to the Y direction and spaced substantially in the X direction. However, the lines of the auxiliary grating 36 are skewed fractionally with respect to the Y direction (typically by the order of about one degree), and thus light passing through the auxiliary grating 36 will be diffracted into a plurality of orders (+1,0,-1) spaced apart in the X direction and each shifted fractionally relative to each other in the Y direction. A periodic light pattern will be produced at the analyser grating 28 in respect of each of the said orders, and thus when the readhead 16 moves relative the scale 10 in the Y direction each of the individual light patterns will produce a light intensity modulation. However, since each of the patterns is shifted fractionally relative to each other image in the Y direction, a plurality of intensity modulations occurring in a phase-shifted relationship will result. The construction and function of the auxiliary grating 36 are described more fully in our co-pending international application case WO 89/05440. Each individual intensity modulation is focused by focusing optics (not shown) onto a photo-detector of a photo-detector array 40, which generates an electrical signal corresponding to the intensity of light incident thereon.
In order to generate a periodic light pattern at the analyser grating 28 in accordance with the teaching of GB 1,504,691, the distance between the index grating 22 and the scale 10 must be equal to the distance between the scale 10 and the analyser grating 28. This condition is automatically fulfilled provided the readhead is constructed so that the distances q and r are equal, since the distance p is common to both the incident and reflected paths. The commonality of the distance p to both the incident and reflected paths makes the readhead insensitive to variations in the distance between the scale 10 and readhead, i.e. movements of the readhead relative to the scale 10 in the Z direction. This makes this type of scale and readhead particularly suitable for use as a transducer in a measuring probe, used to determine deflection of a stylus holding member relative to a fixed structure in a given direction (an example of a measuring probe with which the present invention may be used is described in our U.S. Pat. No. 4,078,314).
Referring now to FIG. 2, a practical embodiment of a three-dimensional transducer arrangement for use in a measuring probe such as the probe mentioned above is illustrated. In the illustrated arrangement, it is envisaged that the readhead system 100 would be supported on the fixed part of a measuring probe, whereas the three scales 110,120,130 are provided on the movable (i.e. stylus-carrying) structure of such a measuring probe. The transducer system 100 comprises a right-angle bracket 140, which performs a supporting function for all the optical elements which make up the readhead system 100. The readhead system 100 consists of three individual readheads 142,144,146 for measuring displacement of the movable structure relative to the fixed structure in the X,Y and Z directions respectively. Each of the readheads has an emitter and a detector carried in the right-angle bracket 140, and for clarity these are schematically indicated in FIG. 2 by the letters E and D respectively. Each individual readhead 142,144,146 comprises an index and analyser grating; for example readhead 144 comprises an index grating 148 and an analyser grating 150. Both the index grating 148 and analyser grating 150 are supported by the bracket 140. An auxiliary grating 152, provided to generate plurality of phase-shifted light intensity modulations at the surface of the analyser grating 150, is positioned directly in front of the analyser grating 150. The auxiliary grating 152 is provided in aperture 154 which restricts the amount of light passing through the grating 152; this provides easier separation of the phase-shifted light intensity modulations at the surface of the analyser 150. A single beam splitting element 156 is provided for all the readheads, the beam splitter 156 taking the form of a rectangular parallelepiped.
Since the index and analyser gratings on the readheads 142,146 extend in the same direction, a single grating may be used for each of the index and analyser gratings of the readheads 142 or 146. Each of the readheads 142,146 has an auxiliary grating 158,160, serving the same function as for the readhead 144. In the preferred feature of this embodiment, both the index and analyser gratings of the readheads 142,144,146 are provided on a single glass plate, as are the auxiliary gratings 152,158,160. This provides easier assembly of the readhead system 100.
It is not essential to employ auxiliary gratings to generate phase-shifted light intensity modulations. Other means may be employed such as the provision of a plurality of offset analyser gratings each of which yields a distinct phase. Furthermore, it is not essential to provide an analyser grating. An analyser as described in GB 1,231,029 may be provided. | An opto-electronic scale reading apparatus comprises a light source (20) which projects light via an index grating (22) onto a reflective scale (10). Light is reflected from the scale (10), passes through an auxiliary grating (36) and is incident upon an analyser grating (28), at which a plurality of periodic light patterns are formed. Light from the light source (20) travels initially parallel to the scale plane, and is subsequently deflected through 90° by a beam splitter cube (26); the light is thus incident upon and reflected and off the scale (10) at 90° to the scale plane. This arrangement enables large movements of the readhead in a direction perpendicular to the scale. | 6 |
RELATED APPLICATIONS
This application is related to U.S. patent application Ser. No. 14/815,110, titled “Operator Identification and Performance Tracking”, filed concurrently with this application, incorporated herein by reference.
FIELD OF INVENTION
This invention relates to robotic navigation using semantic mapping and more particularly to robotic navigation using semantic mapping to navigate robots throughout a warehouse in robot-assisted product order-fulfillment systems.
BACKGROUND
Ordering products over the internet for home delivery is an extremely popular way of shopping. Fulfilling such orders in a timely, accurate and efficient manner is logistically challenging to say the least. Clicking the “check out” button in a virtual shopping cart creates an “order.” The order includes a listing of items that are to be shipped to a particular address. The process of “fulfillment” involves physically taking or “picking” these items from a large warehouse, packing them, and shipping them to the designated address. An important goal of the order-fulfillment process is thus to ship as many items in as short a time as possible.
The order-fulfillment process typically takes place in a large warehouse that contains many products, including those listed in the order. Among the tasks of order fulfillment is therefore that of traversing the warehouse to find and collect the various items listed in an order. In addition, the products that will ultimately be shipped first need to be received in the warehouse and stored or “placed” in storage bins in an orderly fashion throughout the warehouse so they can be readily retrieved for shipping.
In a large warehouse, the goods that are being delivered and ordered can be stored in the warehouse very far apart from each other and dispersed among a great number of other goods. With an order-fulfillment process using only human operators to place and pick the goods requires the operators to do a great deal of walking and can be inefficient and time consuming. Since the efficiency of the fulfillment process is a function of the number of items shipped per unit time, increasing time reduces efficiency.
Robot assisted order-fulfillment systems have been used to increase efficiency and productivity. However, there is still a need to further increase efficiency in such systems.
SUMMARY
In one aspect, the invention features a method for performing tasks on items located in a space using a robot, the items being located proximate fiducial markers, each fiducial marker having a fiducial identification. The method comprises receiving an order to perform a task on at least one item and determining the fiducial identification associated with the at least one item. The method also includes obtaining, using the fiducial identification of the at least one item, a set of coordinates representing a position of the fiducial marker with the determined fiducial identification, in a coordinate system defined by the space, The method further includes navigating the robot to the coordinates of the fiducial marker associated with said determined fiducial identification.
In other aspects of the invention one or more of the following features may be included. The method may further include communicating with a human operator to perform the task on the at least one item, wherein the task includes one of retrieving the at least one item and placing it on the robot or removing the at least one item from the robot and storing it proximate the fiducial marker. The space may be a warehouse containing a plurality of items stored in a plurality of containers dispersed throughout the warehouse. Each fiducial marker may be associated with and located proximate to one or more of the containers. The step of determining the fiducial identification may include establishing a fiducial identification system based on a physical layout of the containers dispersed throughout the warehouse and associating each container to a fiducial identification corresponding to the physical location of the container in the warehouse. The step of associating each container to a fiducial identification may further include linking the fiducial identification of the container to the items. The step of determining the set of coordinates representing a position of the fiducial marker with the determined fiducial identification may include correlating the determined fiducial identification with its corresponding fiducial marker and retrieving a set of coordinates representing the position of said fiducial marker in the coordinate system of the warehouse. Retrieving the set of coordinates representing the position of said fiducial marker may include determining a pose for the fiducial marker within the warehouse and the step of navigating may include propelling the robot to the pose without using intermediate fiducial markers to guide the robot to the fiducial marker correlated to the determined fiducial identification. The step of navigating may further include using a predetermined map of the warehouse including a pose for each fiducial marker to guide the robot to the fiducial marker.
In another aspect of this invention there is a robot configured to perform tasks on items located in a space, the items being located proximate fiducial markers, each fiducial marker having a fiducial identification. The robot includes a processor configured to determine a fiducial identification associated with at least one item on which the robot is to perform a task. The robot is further configured to obtain, using the fiducial identification of the at least one item, a set of coordinates representing a position of the fiducial marker with the determined fiducial identification, in a coordinate system defined by the space. There is a navigation system configured to navigate the robot to the coordinates of the fiducial marker associated with the determined fiducial identification.
In other aspects of the invention one or more of the following features may be included. The robot may include an interface device configured to communicate with a human operator to perform the task on the at least one item. The task may include one of retrieving the at least one item and placing it on the robot or removing the at least one item from the robot and storing it proximate the fiducial marker. The space may be a warehouse containing a plurality of items stored in a plurality of containers dispersed throughout the warehouse. Each fiducial marker may be associated with and located proximate to one or more of the containers. Each container in the warehouse may be associated to a fiducial identification corresponding to the physical location of the container in the warehouse. The fiducial identification of the container may be linked to the items stored in the containers. The processor may further be configured to correlate the determined fiducial identification with its corresponding fiducial marker and retrieve a set of coordinates representing the position of said fiducial marker in the coordinate system of the warehouse. The processor may further be configured to determine a pose for the fiducial marker within the warehouse and the navigation system may be configured to propel the robot to the pose without using intermediate fiducial markers to guide the robot to the fiducial marker correlated to the determined fiducial identification. The navigation system may include a map of the warehouse with a pose for each fiducial marker.
These and other features of the invention will be apparent from the following detailed description and the accompanying figures, in which:
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a top plan view of an order-fulfillment warehouse;
FIG. 2 is a perspective view of a base of one of the robots used in the warehouse shown in FIG. 1 ;
FIG. 3 is a perspective view of the robot in FIG. 2 outfitted with an armature and parked in front of a shelf shown in FIG. 1 ;
FIG. 4 is a partial map of the warehouse of FIG. 1 created using laser radar on the robot;
FIG. 5 is a flow chart depicting the process for locating fiducial markers dispersed throughout the warehouse and storing fiducial marker poses;
FIG. 6 is a table of the fiducial identification to pose mapping;
FIG. 7 is a table of the bin location to fiducial identification mapping; and
FIG. 8 is a flow chart depicting product SKU to pose mapping process; and
DETAILED DESCRIPTION
Referring to FIG. 1 , a typical order-fulfillment warehouse 10 includes shelves 12 filled with the various items that could be included in an order 16 . In operation, the order 16 from warehouse management server 15 arrives at an order-server 14 . The order-server 14 communicates the order 16 to a robot 18 selected from a plurality of robots that roam the warehouse 10 .
A typical robot 18 , shown in FIG. 2 , includes an autonomous wheeled base 20 having a laser-radar 22 . The base 20 also features a transceiver 24 that enables the robot 18 to receive instructions from the order-server 14 , and a camera 26 . The base 20 also features a processor 32 that receives data from the laser-radar 22 and the camera 26 to capture information representative of the robot's environment and a memory 34 that cooperate to carry out various tasks associated with navigation within the warehouse 10 , as well as to navigate to fiducial marker 30 placed on shelves 12 , as shown in FIG. 3 . Fiducial marker 30 (e.g. a two-dimensional bar code) corresponds to bin/location of an item ordered. The navigation approach of this invention is described in detail below with respect to FIGS. 4-8 .
While the description provided herein is focused on picking items from bin locations in the warehouse to fulfill an order for shipment to a customer, the system is equally applicable to the storage or placing of items received into the warehouse in bin locations throughout the warehouse for later retrieval and shipment to a customer. The invention could also be utilized with other standard tasks associated with such a warehouse system, such as, consolidation of items, counting of items, verification, and inspection.
An upper surface 36 of the base 20 features a coupling 38 that engages any one of a plurality of interchangeable armatures 40 , one of which is shown in FIG. 3 . The particular armature 40 in FIG. 3 features a tote-holder 42 for carrying a tote 44 that receives items, and a tablet holder 46 for supporting a tablet 48 . In some embodiments, the armature 40 supports one or more totes for carrying items. In other embodiments, the base 20 supports one or more totes for carrying received items. As used herein, the term “tote” includes, without limitation, cargo holders, bins, cages, shelves, rods from which items can be hung, caddies, crates, racks, stands, trestle, containers, boxes, canisters, vessels, and repositories.
Although a robot 18 excels at moving around the warehouse 10 , with current robot technology, it is not very good at quickly and efficiently picking items from a shelf and placing them on the tote 44 due to the technical difficulties associated with robotic manipulation of objects. A more efficient way of picking items is to use a local operator 50 , which is typically human, to carry out the task of physically removing an ordered item from a shelf 12 and placing it on robot 18 , for example, in tote 44 . The robot 18 communicates the order to the local operator 50 via the tablet 48 , which the local operator 50 can read, or by transmitting the order to a handheld device used by the local operator 50 .
Upon receiving an order 16 from the order server 14 , the robot 18 proceeds to a first warehouse location, e.g. shown in FIG. 3 . It does so based on navigation software stored in the memory 34 and carried out by the processor 32 . The navigation software relies on data concerning the environment, as collected by the laser-radar 22 , an internal table in memory 34 that identifies the fiducial identification (“ID”) of fiducial marker 30 that corresponds to a location in the warehouse 10 where a particular item can be found, and the camera 26 to navigate.
Upon reaching the correct location, the robot 18 parks itself in front of a shelf 12 on which the item is stored and waits for a local operator 50 to retrieve the item from the shelf 12 and place it in tote 44 . If robot 18 has other items to retrieve it proceeds to those locations. The item(s) retrieved by robot 18 are then delivered to a packing station 100 , FIG. 1 , where they are packed and shipped.
It will be understood by those skilled in the art that each robot may be fulfilling one or more orders and each order may consist of one or more items. Typically, some form of route optimization software would be included to increase efficiency, but this is beyond the scope of this invention and is therefore not described herein.
In order to simplify the description of the invention, a single robot 18 and operator 50 are described. However, as is evident from FIG. 1 , a typical fulfillment operation includes many robots and operators working among each other in the warehouse to fill a continuous stream of orders. In addition, certain robots and operators may be performing a placing or storage task to stock the warehouse with items or other tasks such as consolidation of items, counting of items, verification, and inspection.
The navigation approach of this invention, as well as the semantic mapping of a SKU of an item to be retrieved to a fiducial ID/pose associated with a fiducial marker in the warehouse where the item is located, is described in detail below with respect to FIGS. 4-8 .
Using one or more robots 18 , a map of the warehouse 10 must be created and the location of various fiducial markers dispersed throughout the warehouse must be determined. To do this, one of the robots 18 navigates the warehouse and builds a map 10 a , FIG. 4 , utilizing its laser-radar 22 and simultaneous localization and mapping (SLAM), which is a computational problem of constructing or updating a map of an unknown environment. Popular SLAM approximate solution methods include the particle filter and extended Kalman filter. The SLAM GMapping approach is the preferred approach, but any suitable SLAM approach can be used.
Robot 18 utilizes its laser-radar 22 to create map 10 a of warehouse 10 as robot 18 travels throughout the space identifying, open space 112 , walls 114 , objects 116 , and other static obstacles, such as shelf 12 , in the space, based on the reflections it receives as the laser-radar scans the environment.
While constructing the map 10 a or thereafter, one or more robots 18 navigates through warehouse 10 using camera 26 to scan the environment to locate fiducial markers (two-dimensional bar codes) dispersed throughout the warehouse on shelves proximate bins, such as 32 and 34 , FIG. 3 , in which items are stored. Robots 18 use a known starting point or origin for reference, such as origin 110 . When a fiducial marker, such as fiducial marker 30 , FIGS. 3 and 4 , is located by robot 18 using its camera 26 , the location in the warehouse relative to origin 110 is determined.
By the use of wheel encoders and heading sensors, vector 120 , and the robot's position in the warehouse 10 can be determined. Using the captured image of a fiducial marker/two-dimensional barcode and its known size, robot 18 can determine the orientation with respect to and distance from the robot of the fiducial marker/two-dimensional barcode, vector 130 . With vectors 120 and 130 known, vector 140 , between origin 110 and fiducial marker 30 , can be determined. From vector 140 and the determined orientation of the fiducial marker/two-dimensional barcode relative to robot 18 , the pose (position and orientation) defined by a quaternion (x, y, z, ω) for fiducial marker 30 can be determined.
Flow chart 200 , FIG. 5 , describing the fiducial marker location process is described. This is performed in an initial mapping mode and as robot 18 encounters new fiducial markers in the warehouse while performing picking, placing and/or other tasks. In step 202 , robot 18 using camera 26 captures image and in step 204 searches for fiducial markers within the captured images. In step 206 , if a fiducial marker is found in the image (step 204 ) it is determined if the fiducial marker is already stored in fiducial table 300 , FIG. 6 , which is located in memory 34 of robot 18 . If the fiducial information is stored in memory already, the flow chart returns to step 202 to capture another image. If it is not in memory, the pose is determined according to the process described above and in step 208 , it is added to fiducial to pose lookup table 300 .
In look-up table 300 , which may be stored in the memory of each robot, there are included for each fiducial marker a fiducial identification, 1, 2, 3, etc, and a pose for the fiducial marker/bar code associated with each fiducial identification. The pose consists of the x,y,z coordinates in the warehouse along with the orientation or the quaternion (x, y, z, ω).
In another look-up Table 400 , FIG. 7 , which may also be stored in the memory of each robot, is a listing of bin locations (e.g. 402 a - f ) within warehouse 10 , which are correlated to particular fiducial ID's 404 , e.g. number “11”. The bin locations, in this example, consist of seven alpha-numeric characters. The first six characters (e.g. L01001) pertain to the shelf location within the warehouse and the last character (e.g. A-F) identifies the particular bin at the shelf location. In this example, there are six different bin locations associated with fiducial ID “11”. There may be one or more bins associated with each fiducial ID/marker.
The alpha-numeric bin locations are understandable to humans, e.g. operator 50 , FIG. 3 , as corresponding to a physical location in the warehouse 10 where items are stored. However, they do not have meaning to robot 18 . By mapping the locations to fiducial ID's, Robot 18 can determine the pose of the fiducial ID using the information in table 300 , FIG. 6 , and then navigate to the pose as described herein.
The order fulfillment process according to this invention is depicted in flow chart 500 , FIG. 8 . In step 502 , warehouse management system 15 , FIG. 1 , obtains an order, which may consist of one or more items to be retrieved. In step 504 the SKU number(s) of the items is/are determined by the warehouse management system 15 , and from the SKU number(s), the bin location(s) is/are determined in step 506 . A list of bin locations for the order is then transmitted to robot 18 . In step 508 , robot 18 correlates the bin locations to fiducial ID's and from the fiducial ID's, the pose of each fiducial ID is obtained in step 510 . In step 512 the robot 18 navigates to the pose as shown in FIG. 3 , where an operator can pick the item to be retrieved from the appropriate bin and place it on the robot.
Item specific information, such as SKU number and bin location, obtained by the warehouse management system 15 , can be transmitted to tablet 48 on robot 18 so that the operator 50 can be informed of the particular items to be retrieved when the robot arrives at each fiducial marker location.
With the SLAM map and the pose of the fiducial ID's known, robot 18 can readily navigate to any one of the fiducial ID's using various robot navigation techniques. The preferred approach involves setting an initial route to the fiducial marker pose given the knowledge of the open space 112 in the warehouse 10 and the walls 114 , shelves (such as shelf 12 ) and other obstacles 116 . As the robot begins to traverse the warehouse using its laser radar 26 , it determines if there are any obstacles in its path either fixed or dynamic, such as other robots 18 and/or operators 50 and iteratively updates its path to the pose of the fiducial marker. The robot re-plans its route about once every 50 milliseconds, constantly searching for the most efficient and effective path while avoiding obstacles.
With the product SKU/fiducial ID to fiducial pose mapping technique combined with the SLAM navigation technique both described herein, robots 18 are able to very efficiently and effectively navigate the warehouse space without having to use more complex navigation approaches typically used which involve grid lines and intermediate fiducial markers to determine location within the warehouse. | A method for performing tasks on items located in a space using a robot, the items being located proximate fiducial markers, each fiducial marker having a fiducial identification. The method includes receiving an order to perform a task on at least one item and determining the fiducial identification associated with the at least one item. The method also includes obtaining, using the fiducial identification of the at least one item, a set of coordinates representing a position of the fiducial marker with the determined fiducial identification, in a coordinate system defined by the space. The method further includes navigating the robot to the coordinates of the fiducial marker associated with said determined fiducial identification. | 6 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a method, an apparatus, and an article of manufacture for electronically developing, generating, integrating, reviewing, maintaining and reporting the risk management file and safety assurance case.
[0002] Medical device safety has impact on everyone's life, and is FDA's primary concern. Being able to demonstrate the product safety is essential for the public to be assured on safety and for the medical device manufacturers to succeed as a business entity. Medical device risk management and safely assurance is the central method in managing the safety of the medical devices, and is one of the most complex yet critical quality system disciplines as it involves almost every aspect of the manufacturer operations. Practices and approaches or risk management are widely spread across the industry. Over the decades, the international medical device community has been working on continuously improving the risk management standard. As such, ISO 14971 2007 has been introduced and become recognized by FDA since 2009. Comparing to previous version of the standards. ISO 14971 is a long haul from its previous version. It has been a challenge for the medical device industry to keep up with this state of the art standard, which requires life cycle approach and involves almost every stage and every aspect of the product life cycle: product realization, production, and commercialization. On the other side, over the years, FDA has been encouraging the medical device industry to adapt the assurance ease method to demonstrate safety. In addition, FDA has initiated infusion pump safety improvement initiative, and issued the new guidance on infusion pump in 2010: Total Product Life Cycle: Infusion Pump—Premarket Notification |510(k)| Submissions. The new guidance requires the safety assurance case for product clearance.
SUMMARY OF THE PROBLEMS TO SOLVE
[0003] Medical device manufacturers such as infusion pump manufacturers need comply with international standard on risk management—ISO 14971, which requires maintaining a risk management file for each product, as well as FDA's guidance: Total Product Life Cycle Management—Infusion Pump, which requires Safely Assurance Case for infusion pump 510(k) submission. Currently the medical device manufacturers don't have enough practical methods or tools on
1. How to electronically centralize and maintain the risk management file through the product life cycle 2. How to automatically integrate and synchronize the risk management file and safely assurance case through the product life cycle 3. How to automatically develop and present a safety assurance ease that is readable and maintainable for a complex system such as infusion pump 4. How to electronically submit safety assurance case to FDA 5. How to electronically manage assurance case reviews within FDA
Summary of what Currently Exists
[0000]
1. Device manufacturers mostly manually manage the risk management report document in demonstrating the maintenance of the risk management file. This becomes particularly challenging when there are many design or process changes over the product life cycle post product's initial commercialization.
2. The risk management file is spread out across many different places/stages/systems. which can easily lead to incomplete information, broken reference link, not connected or synchronized information, which then could lead to mishandling safely issues that potentially result in safety issues to the patents or the public.
3. Safety assurance ease development required by FDA guidance and risk management activities required by ISO14971 are carried out separately. This creates redundancy and duplication, as well as synchronization issues.
4. The graphic editor tools such as Adelard ASCE Software, Microsoft Visio are the only tools used to develop safety assurance case. This method has challenges for maintenance and connectivity, and can potentially lead to errors that could result in product safety or compliance issues. In addition, assurance case generated graphically using existing method is hard for navigation and review, particularly for a complex system such as infusion pump.
5. Due to the complexity involving multiple areas of expertise, assurance case review by regulatory agencies typically lakes a team effort. It is difficult for regulatory agencies to manage assurance case reviews and ensure consistency without an electronic review management tools.
SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to address many of the challenges associated above. Specifically the objects of the present invention are:
1. Provide a centralized and living mechanism/tool in assuring and demonstrating medical device safely at ongoing basis 2. Improve communications among the medical device manufacturer, medical device user facilities (such as hospitals) and regulatory agencies (e.g. FDA) 3. Improve efficiency and reduce cost for manufacturers, and regulatory reviewers (e.g. FDA) 4. Promote medical device safety
[0019] The above objects and advantages of the present invention are achieved by a method, an apparatus, and an article of manufacture for intuitive facilitation of the compiling, review, maintenance, and regulatory submission of the risk management file and safely assurance case. The method comprise: means for connecting electronically an electronic intermediary to a device manufacturer, and regulatory agencies: means for collecting electronically risk management file and safety assurance case data from said device manufacturer; means for electronically processing said data to generate and present safety assurance case: means for electronically centralizing and maintaining the risk management file through the product life cycle: means for integrating of risk management file and safety assurance case through the product life cycle: means for electronically submitting the assurance case electronically to regulatory agencies: means for electronically managing safety assurance case reviews within FDA.
[0020] Further, the apparatus of the present invention comprises a general purpose computer programmed with software to operate the general purpose computer in accordance with the present invention. In particular, the apparatus comprises: means for connecting electronically an electronic intermediary to a device manufacturer, and regulatory agencies; means for collecting electronically risk management file and safety assurance case data from said device manufacturer, means for electronically processing said data to generate and present safety assurance case; means for electronically centralizing and maintaining the risk management file through the product life cycle: means for integrating of risk management file and safety assurance case through the product life cycle; means for electronically submitting the assurance case electronically to regulatory agencies; means for electronically managing safety assurance case reviews within regulatory agencies; means for electronically assuring quality system compliance in a real time manner.
[0021] Furthermore, the article of manufacture of the present invention comprises a computer-readable medium embodying a computer program. For the present invention, the computer-readable medium embodying the computer program comprises code segments to control a general purpose computer to perform the method of the present invention. Non-limiting examples of a “computer-readable medium” include a magnetic hard disk, a floppy disk, an optical disk, a magnetic tape, a memory chip, and a carrier wave used to carry electronic data, such as those used in transmitting and receiving electronic mail or in accessing an electronic data network, such as the Internet. Further, non-limiting examples of “code segments” include software, instructions, computer programs, or any means for controlling a general purpose computer.
[0022] Moreover, the above objects and advantages of the present invention are illustrative, and not exhaustive, of those which can be achieved by the present invention. Thus, these and other objects and advantages of the present invention will be apparent from the description herein or can be learned from practicing the invention, both as embodied herein and as modified in view of any variations which may be apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 illustrates the relationships of the invention.
[0024] FIG. 2 illustrates the procedure of the invention.
[0025] FIG. 3 illustrates the example of the table tree format assurance case
[0026] FIG. 4 illustrates the example of the graphical format Assurance Case
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Referring now to the accompanying drawings, wherein similar reference characters refer to similar reference parts throughout the drawings. FIGS. 1 , 2 and 3 depict the procedure used in the preferred embodiment for a method, an apparatus, and an article of manufacture for facilitating risk management file and assurance case creation, centralization, review, maintenance, and submission.
[0028] Step/Element 4 . Product Life Cycle Safely Related Events and Information:
[0029] In this step, the Manufacturer task initiator ( 30 ) initiates a task triggered by a product life cycle event or information that could result in risk management file and safety assurance case update. The events could happen through the product life cycle including pre-production design and development phase, production manufacturing stage, or post-production on-market stage. Specific examples would include a new or functionality feature, a feature or functionality change, a new design progress, a design change, a process change, an issues found, or a document record that need broad review/approval. The initiator will describe the event and provide the additional information as appropriate including attaching additional documents or files. The manufacturer risk management file and safely assurance case owner will assign the task to an individual (such as a team member) as the task owner ( 32 ). The task owner provides the Analysis and Resolutions to address the task assigned including provide task progress updates.
[0030] Step/Element 6 , Industry Guidance
[0031] The electronic intermediary provides a link to a website where is maintained to capture the latest industry guidance associated to risk management and safety assurance ease as related to a particular category of tasks. Examples of the guidance include the latest updated expectations/guidance from FDA, enforcement actions, latest industry standards/guidance, tools, and training/seminars. The frequency of the update can be periodic or as needed.
[0032] Step/Element 8 , Manufacture Internal Instructions
[0033] The electronic intermediary provides the capability for the manufacturer super user to provide the internal instructions to internal users based on the latest SOPs or any relevant quality system update. The electronic intermediary provides the capability for the manufacture regular users to access.
[0034] Step/Element 10 , Hazard Analysis
[0035] In this step, the electronic intermediary will prompt user to review and update as needed the hazard causal tree. The causal tree starts with lop level hazards, then the associated hazard situations, and then deductively break down to next level sub-causes, so on and so forth.
[0036] Step/Element 12 , Risk Assessment and Evaluation
[0037] In the step of the Risk Analysis, The electronic intermediary will allow user to navigate through the hazard causal tree. For each hazard/the user will provide the pre-control and post-control risk assessment results associated to each hazard situations, or corresponding causes/sub-causes. The assessment will include the severity and probability. The electronic intermediary will prompt user to provide any assumptions used for risk assessment. The electronic intermediary will prompt user to provide rationales on the completeness of the sub-causes identified. The electronic intermediary will also prompt user to provide argument for the sufficiency of the controls if there arc direct controls associated to the hazards/causes/sub-causes. The electronic intermediary will prompt user to provide the reference evidence to support the assumptions, completeness rationales, and sufficiency argument as applicable
[0038] Step/Element 14 , Control Analysis
[0039] In the step of the control analysis, the electronic intermediary will prompt user to add applicable controls to mitigate the risks indentified. The electronic intermediary will prompt user to select the controls options, describe the control requirements, and identify objectives in terms of whether it is reducing severity or probabilities. The electronic intermediary will prompt user to provide argument/implementation strategy on how to implement design traceability, validation, and verification. The electronic intermediary will prompt user to provide the design documents/references to demonstrate the control requirements traceability, validation documents to demonstrate the effectiveness of the control requirement, and verification document to demonstrate the correct implementation of the requirements.
[0040] Step/Element 16 , Assurance Case
[0041] In the step of assurance case, the electronic intermediary will process the data and present in a tree table formal assurance case or graphic format assurance case: The electronic intermediary will automatically convert the hazard causal tree into claims tree. In addition, the electronic intermediary will automatically convert the control requirements as sub-claims for the hazard causal claims the controls are against. As the results, the claim tree will compose of all hazards/causes claiming every element (hazard, cause or sub-causes) have been mitigated to be acceptable, as well as all the claims of the controls have been implemented and effective. It is possible that one hazard/cause have multiple control claims. It is possible that a hazard/cause claim has sub-claims of both sub-cause claims and direct control claims. For each hazard claim, the electronic intermediary will automatically convert the applicable risks and risk assessment and evaluation results pre-control and post-control collected as the claim context for the assurance case hazard claims. For each control claim, the electronic intermediary will automatically convert the risk reduction objective, and the risk control category collected as the claim context for the assurance case control claims. For each hazard claim, the electronic intermediary will automatically convert the risk assessment assumptions, and rationales for the completeness of the sub-claims, and rationales for the effectiveness of the controls as part of the argument/strategy for the assurance case hazard claims. For each control claim, the electronic intermediary will automatically convert the strategy/strategy on the validation of the control effectiveness, the design traceability, and the verification of the correct implementation of the control as part of the argument/strategy for the assurance control claim. For each hazard claim or control claim, the electronic intermediary will automatically convert evidence/reference under the risk analysis or control analysis as the evidence/reference for the assurance ease. The electronic intermediary will present the assurance case a tree table format with following columns: claim tree (on the very left side of the table for easy navigation), risk analysis context, strategy/argument/assumptions. and evidence/reference. Each rows represents a assurance case pattern of what is the claim, what is the context for the claim, what is the strategy/argument for the claim including any assumptions made, and finally what is the corresponding evidence supporting the argument including assumptions. If there are any sub-claims, it will be represented as sub-branches under the claim of the tree. FIG. 3 illustrates the example of the table tree format Assurance Case. The electronic intermediary will also present the assurance case in a graphical format. FIG. 4 illustrates the example of the graphical formal Assurance Case.
[0042] 8 . Checklist
[0043] To ensure in rather real time manner that a task is completed in a compliant manner, the electronic intermediary provide a checklist for user to validate all the quality and compliance criteria is met before a task can be closed. Super User will be able to customize the checklist per internal operating procedures as well.
[0044] 9 . Electronic Signatures Review and Approval
[0045] Upon completion of all the required elements for a task, the task owner can submit to list of approvers for final review and sign off. The list of the approvers is customized by each manufacturer per internal operation procedures. The approvers will receive an e-mail notice for review/approval. The approvers can choose either approve or reject. The electronic signature information including who, when, which task will be captured lo demonstrate compliance. The electronic signatures are in compliant with FDA regulations CFR 820 Part 11. | An electronic intermediary electronically connects with a medical device manufacturer and regulatory agencies, collects and processes electronically product life cycle safely related events and information from a medical device manufacturer. The electronic intermediary processes the information collected electronically, integrates, generates, maintains, presents and distributes the risk management file and safely assurance case through the product life cycle using, linking, and connecting the collected and processed data. | 6 |
This invention is about refinements added to the process of setup and manufacturing of thermoplastic containers, such as bottles, that have a curved central section in the bottom, from rough shapes that too have a curved central section in the bottom with an inward convexity, the process containing at least a heating period of at least the body of the rough shape to bring the thermoplastic material to its softening temperature, a step during which the rough shape is positioned in a finishing mold designed to achieve the finished container, this finishing mold notably possessing a curved central section mold bottom whose dimensions allow it to be inserted in the hollow at the bottom of the rough shape, and a finishing step of blowing of the rough shape during which the curved central section of the mold is inserted into the hollow central section of the bottom of the rough shape.
BACKGROUND OF THE INVENTION
Processes and setups to obtain containers from rough shapes are now well-known. These allow the user to obtain containers that are able to sustain high temperatures and relatively severe mechanical pressure without losing their shape during use. In such processes, the molding is performed by blowing or by stretch-blowing, from a pre-form made of thermoplastic material whose body is brought to a temperature at least equal to the softening temperature of the material, and this results in an intermediary container of larger size than the finished container yet to be obtained; this intermediary container is then heated to obtain a rough shape of heated, shrunk body, which is then molded to form the final container.
Such processes and installation are, for example, known as European patent EP 442 836 in the name of the applicant.
Despite the fact that this process was vastly superior to previous techniques, it became obvious that the containers obtained by this process had a tendency to lose their shape when filled with hot liquids, and this made the container unstable. Then, the bottom structure itself was reworked, and it was found that the containers that had a curved bottom with an inward convexity, in other words containers with a “champagne bottom” because of the shape of the bottom which resembles that of a champagne bottle, could resist satisfactorily to these conditions.
The various processes and setups were tested and resulted in this type of final container bottom shape. It was determined that the containers that possess the best thermal or mechanical properties during use are those obtained from a rough shape possessing at least a curved primer of inward convexity in the central area, at the bottom on the final container. It was even noted that in certain applications that the rough shape must have a bottom whose shape and measurement must correspond to those of the bottom of the final recipient.
Therefore, the French patent request No 95 01507 presents a process and a setup that obtains a particular champagne-bottomed container from a rough shape whose bottom possesses the shape and size of the bottom of the final container.
Contrarily to the intermediary container and to the final container that are both obtained in a mold, the rough shape is obtained in air, after highly heating the body of the container and thus having provoked a relaxing of the constraints conferred to the thermoplastic material during the transformation of the pre-shape into the intermediary container. The result is that the rough shape resembles a container whose body is vaguely deformed or bloated, but that nevertheless possesses a bottom zone with a shape and dimension predetermined by the process used, that is to say either the final shape of the bottom of the final container, or a primer of the central part of the final container.
But, because of the relative indetermination of the shape of the body of the rough shape, it happens relatively often that the symmetry axis of the bottom zone is offset and/or tilted in relation to the axis of the finishing mold at the moment when the rough shape is placed inside of it. Actually, the positioning of the rough shape in the finishing mold is performed in the known manner with the neck, which is the only part that undergoes no deformation during the different steps of the transformation from a pre-shape to the final container.
The result is that sometimes the bottom area of the rough shape is not correctly centered at the moment of contact with the curved shape of the bottom of the mold, which often causes the bottom of the rough shape to get stuck on the curved shape of the bottom mold in an offset and/or tilted position, causing the final container to be misshapen and unsatisfactory.
SUMMARY OF THE INVENTION
The invention's goal is to remedy this inconvenience, proposing a process and setup allowing the user to obtain a correct centering of the central curved zone of the rough shape in relation to the curved area of the mold bottom.
The goals of the invention are attained by setting up a process such as described in the introduction that is characterized in that, to facilitate the centering of the bottom of the rough shape in relation to the curved central part of the mold bottom, a relative rotation movement between the curved area of the mold bottom and the central part of the rough shape central is performed from the moment that the rough shape is placed into the mold to the moment where the shapes are correctly positioned in relation one to another.
In fact, the relative rotation movement between the bottom of the rough shape and the bottom of the mold increases the sliding of the material on the central section of the bottom of the mold, thus allowing a correct centering.
Preferably, and according to another characteristic, the relative rotation movement is performed by rotating at least the central curved part of the bottom of the mold. Alternatively, even though this is more difficult to achieve, the relative rotation movement is achieved by turning the rough shape within the mold.
The invention also has for a goal a setup for the implementation of the process, characterized in that it can trigger the relative rotation of the rough shape and of the mold bottom.
In a preferred implementation, the means to trigger the relative rotation between the rough shape and the central section of the mold bottom are made up of a pneumatic rotary motor that powers the central part. This solution is particularly advantageous because the container assembly lines already possess the pressurized fluid distribution system as much to blow the containers as to move sections of the assembly line. It is noted that the mold bottom can generally be moved along the axis of the mold, at least to facilitate the setting of the rough shape and to facilitate the de-molding of the container. In other cases, the mold bottoms are moved along the same axis during the finishing phase, as it is the case in the French patent application No 95 01507 that this applicant filed, in order to compensate for the slight shrinking that occurs at the beginning of the finishing blowing and allows contact between the bottom of the mold and the bottom of the rough shape. These movements of the bottom of the mold are achieved with pneumatic devices, and it is therefore relatively easy to selectively divert a part of the fluid that serves in the movement of the mold bottom to power the pneumatic rotary motor.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of this invention will appear during the reading of the description that is to follow, in sight of the figures in the appendix, on which:
FIGS. 1 and 2 illustrate, each in a schematic fashion, different possible steps from a container manufacturing process that begins with a pre-shape that is transformed into an intermediary container, which is then thermally treated to obtain a rough shape before blowing the final container.
FIGS. 3 a to 3 c and 4 a to 4 c illustrate in a schematic fashion two variations of a setup for implementation of the invention's process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 illustrate the known steps of the manufacture of a container possessing a hollow bottom going through a finishing step that consists of blowing a rough shape.
An initial pre-shape 1 is placed, after having been submitted to an appropriate heating to soften the thermoplastic material that it is made of, in a first mold (not shown) in which it is blown or stretched then blown, to obtain an intermediary container 2 possessing a bottom with a hollow area 3 , with a convexity turned toward the inside of container 2 .
The intermediary container 2 is then submitted to a heating that allows a freeing of the stresses induced during blowing (or of the stretching-blowing), which leads to a hot rough shape 4 with a longitudinally and transversally shrunken body in relation to the intermediary container.
The preceding steps are examples carried out under general conditions as indicated in the European document EP 0 442 936 mentioned in the introduction. But other methods that the professional in this field will know can be used and/or combined and/or adapted to obtain the desired result.
The rough shape 4 is then submitted to an appropriate thermal treatment to allow it to be treated in the finishing mold (not shown), to obtain the final container 5 .
Preferably, and in a known manner, the neck 6 of the final container is the same, in shape and in size, as that of the pre-form. It is not submitted to dimensional modifications during the diverse transformation steps.
It is important to remind that a particular thermal treatment can be applied to the rough shape 4 and to its neck 6 to noticeably increase the crystallinity rate of the final container 5 in relation to that which can be obtained by a classical blowing process.
This way, the invention is particularly adapted to the manufacturing of containers capable of withstanding severe thermal or mechanical stresses during use.
The difference between FIGS. 1 and 2 comes from the fact that in the case of FIG. 1, the bottom of the rough shape is slightly different than that of the final container 5 . In fact, the process which steps are illustrated by FIG. 2, known as French patent application 95 01507, consists, among others, of making the intermediary container 2 such as its bottom section 7 will not undergo any more modification during the following steps of shaping of the rough shape 4 and of the finishing blowing.
However, in a known way as well, the process illustrated in FIG. 1 supposes that the thermal treatment applied to the rough shape allows a modification of the bottom during the final blowing, to bring it to its final shape.
As mentioned, the phase of releasing the constraints that yields the rough shape 4 , from the intermediary container 2 , often yields a rough shape 4 whose bottom hollow section 3 symmetry axis 8 is axially offset and/or tilted in relation to the neck's symmetry axis 9 which corresponds to the symmetry axis of the whole of the final container 5 .
As indicated, the mold used during the finishing phase has a curved section in the bottom that is designed to be inserted into the hollow section 3 of the bottom of the rough shape, in order to avoid an uncontrolled deformation of this hollow section. To this effect, the bottom of the mold is axially mobile and is brought in contact with the bottom of the rough shape during the finishing phase. According to the complexity of the finishing process, the bottom of the mold can be brought in contact with the bottom of the rough shape immediately upon closure of the mold, or even, as described in the French patent application published under number 2 714 631 in the name of the applicant, the bottom of the mold can be brought in contact with the bottom of the rough shape during the finishing blowing.
If, as illustrated in FIGS. 1 and 2, the axes 8 —from the bottom of the rough shape 4 —and 9 —passing through the neck—are offset, then a poor positioning of the curved section in the hollow 3 sometimes occurs, and a deformed bottle is obtained.
According to the invention, and as described in FIGS. 3A to 3 C and 4 A to 4 C, a relative rotation between the rough shape 4 and the curved central section 10 of the bottom of the mold 11 is performed.
A first solution, not shown in the drawings, and relatively difficult to achieve, consists of rotating the rough shape relative to the mold. This solution is applicable only if the bottom of the mold in brought into contact with the bottom of the rough shape at the moment the mold is closed. Because after the closure, once the finishing blowing has begun, there is a bloating of the shoulders and of the body of the rough shape that bring the sides of the rough shape in contact with the walls of the mold's cavity. Therefore, if the rough shape rotation solution is used, it is imperative to stop the rotation of the rough shape before the shoulder or the body of the rough shape make contact with the wall of the mold, or the final container will be of poor quality.
Besides, other technological requirements make the other solution more attractive to this one. The other solution, as illustrated in FIGS. 3A to 3 C and 4 A to 4 C, consists of designing the bottom of the mold in order to be able to rotate the central curved section 10 of the bottom 11 .
In the actual process, illustrated in FIGS. 3A to 3 C and 4 A to 4 C, the bottom of the mold 11 , axially mobile in the direction of the finishing mold's axis, is made of at least two parts: the central curved part 10 designed to be rotated around the axis 12 of the bottom, the same as the axis of the mold and of the desired container, and a peripheral section 13 that holds the central rotating part 10 .
Preferably, the peripheral section only moves axially.
In FIGS. 3A to 3 C, the rotation of the curved central section is achieved with the aid of a motor 14 , such as an electrical motor, attached to the block that is the peripheral section of the bottom 11 of the mold. The mold also contains, in the known manner, in addition to the bottom 11 of the mold, two half-molds 15 A and 15 B that determinate the shape and the final size of the body and of the shoulder of the final container 5 .
FIGS. 4A to 4 C illustrate a preferred implementation process of the invention. This implementation uses, for the rotation of the central curved part 10 an pneumatic motor 16 . The structure of such motor is known from diverse applications and will not be detailed in these figures. Such a motor contains a rotary turbine powered by a fluid, such as compressed air, and the rotational motion of the turbine is transmitted to the central part 10 by the means of gears or equivalent means that can be easily implemented by professionals in this field.
It is advantageous to have the pressurized fluid used for the rotation of the pneumatic motor 16 to be for example the compressed air that is used to move a piston 17 which is attached to the bottom of the mold 11 to effect the longitudinal movement of the mold 11 and to bring it into contact with the bottom of the rough shape 4 .
Actually, the bottom of the mold 11 is, in the known manner, attached to the piston 17 , which is mobile within a chamber 18 located in a base 19 . This base 19 is itself mobile, along the longitudinal axis of the molding cavity between a high and a low position. In the high position, the base 19 is fitted within the lower section of the half-molds 15 A and 15 B, and completes the molding cavity. The low position allows the de-molding of the container.
When the base is in the high position, such as on FIGS. 4A and 4C, it is possible to move the piston 17 by using a compressed fluid, such as compressed air, that circulates in the device for the blowing of the containers.
The pressure jack thus created by the piston and the chamber has two purposes, and two ducts 20 and 21 go through the base to end up on either side of the chamber 18 and of the piston 17 .
The first duct 20 allows the bringing of the bottom of the mold 11 in contact with the bottom of the rough shape; the second duct 21 allows the spreading of the bottom of the mold, when lowering it.
To allow the rotation of the pneumatic motor 16 by the fluid bringing the bottom 11 of the molding in contact with the bottom of the rough shape 4 during the finishing, the bottom 11 of the mold is pierced by a duct 22 that opens up against the turbine on one end and that is linked with the chamber 18 on the side where the duct 20 opens up to bring the fluid enabling the displacement of the pressure jack 17 in the direction of the joining of the bottom of the mold and of the bottom of the rough shape.
Thus, when the pressure jack is activated to bring together the bottom of the mold and the bottom of the rough shape, the pneumatic motor is automatically activated.
The variation in FIGS. 3A to 3 C can utilize, for the longitudinal displacement of the bottom of mold, a structure similar to that of FIGS. 4A to 4 C. The only difference is that duct 22 is not necessary, since the motor is electric rather than pneumatically powered.
On FIGS. 3A and 3C is also shown the case when the bottom of the mold 11 is not brought in contact with the bottom of the rough shape 4 at the closure of the mold, but rather progressively brought in contact during the finishing blowing.
Actually, it occurs that during the finishing step, and this has been described and explained in the already mentioned French patent application 2 714 631, that the rough shape is submitted to a height reduction, because of the bloating of the shoulder and of the body which, when making contact with the walls of the mold cavity 15 A and 15 B, cause the bottom to rise, by suction.
In order to avoid over-stretching the sides, the bottom of the mold is raised.
Thus, FIG. 3A shows the phase immediately following the closing of the finishing mold: the rough shape 4 is at maximum length, and the bottom of the mold in its low position.
FIG. 3B shows, in an exaggerated manner, the shape of the rough shape after the beginning of the blowing.
The rough shape has retracted, and its bottom has lifted itself up. The bottom 11 of the mold is being raised, with its central curved section rotating.
FIG. 3C shows the finished container and the position occupied by the bottom of the mold at the end of this phase.
In FIGS. 4A to 4 C is shown the case when the bottom of the mold 11 is brought into contact with the bottom of the rough shape 4 immediately after the closing of the mold.
In FIG. 4A, the bottom 11 of the mold has not yet begun its rise, but the central part 10 is already rotating. To perform this, a pressurized fluid Ps is injected in duct 20 . The raising then begins and the bottom 11 of the mold reaches the position shown on FIG. 4 B.
Also, FIGS. 4A to 4 C illustrate the case when the shape of the bottom of the rough shape does not correspond exactly to that of the bottom of the finished container 5 , and FIG. 4B shows the said container in its near-final shape with the exception of the bottom which is not then completely shaped. FIG. 4C finally shows the finished container 5 and the positions occupied by the container 5 , and by the different elements (walls 15 A, 15 B, and bottom 11 ) of the mold.
The rotation of the curved central section 10 of the bottom of the mold allows a correct centering of the bottom and thus a satisfactory finished container 5 .
It is of course understood that the invention is not limited at all to the described implementations, and rather covers all the variations. | A container ( 5 ) such as a bottle made of thermoplastic material and provided with a bottom wall having an inwardly convex curved central portion ( 3 ) is disclosed. The container is produced by blow moulding a blank ( 4 ) with at least one incipient bottom recess ( 3 ) in a finishing mould ( 15 a , 15 b , 11 ) of which the bottom wall ( 11 ) has an arched central portion ( 10 ) substantially matching the recess in the bottom of the container to be produced. Said container is produced by causing relative rotation of the central portion ( 10 ) and the blank ( 4 ) when said central portion is positioned in the recess in the bottom of the blank. | 8 |
This is a continuation, of application Ser. No. 07/941,449, filed as PCT/EP92/00408, Feb. 24, 1992 published as WO92/14467, Sep. 3, 1992, now abandoned.
TECHNICAL FIELD
The object of the invention is a new therapeutic agent used in the theraputic treatment of cancer tumors, and more particularly, an agent designed for reinforcing the effectiveness of cytotoxic substances used in the treatment of human or animal cancer tumors developing the phenomenon of multiple resistance to anticancer agents (multiple drug resistance: MDR).
BACKGROUND ART
The phenomenon of multiple drug resistance is known, and is not restricted only to anticancer agents. Various explanations have been given to this day, to help understanding the mechanisms involved. Concerning the behavior of the cancer tumor cells, it has been possible to identify several different resistance systems: for example, in relation with the cell membrane permeability, the involvement of a specific glycoprotein (P-gp) has been recognized, but it is accepted that other proteinic factors can be involved.
This phenomenon needs to be addressed in its varied, if not complicated aspects, which makes the investigations aimed at providing proper solutions all the more difficult.
The employment of cytotoxic substances or drugs in the treatment of cancer tumors is confronted with several problems. Firstly, most drugs used for this purpose exhibit a nonspecific inherent toxicity leading to adverse side effects; on the other hand, because of this inherent toxicity, the mounts which can be administered to patients are limited and in numerous cases, the activity needed at the site of the tumors, is not sufficient any more.
Various means have already been proposed for overcoming these problems, such as the use of a vector for the cytotoxic substance, for example through the incorporation into liposomes. In such a case however, though the inherent toxicity of the cytotoxic substance is temporarily masked and hence has limited side effects on the patient, its activity is not always restored at the site of the tumor to the desired level of effectiveness.
Furthermore, should the tumor cells subjected to such a treatment develop the phenomenon of multiple drug resistance--whether this property be innate or acquired--the cytotoxic substance loses almost totally its effectiveness.
Several substances are known to-day which display in vitro an inhibitory activity against MDR: they are mostly noncytotoxic substances, generally of a hydrophobic nature, such as for example alkaloids. In vitro, their concomitant use with a cytotoxic drug appears to be satisfactory, the so-called MDR phenomenon being significantly inhibited at the cellular level, so that the drug is able to fulfil its function unhindered.
The situation is however quite different, when one tries to apply such results to a living body. The substances inhibiting MDR, alkaloids or others, also exhibit an inherent toxicity which limits their administration to beneath a level (serum level) at which the activity desired (MDR inhibition) is already lost. Furthermore, although the cytotoxic substance is administered in its free form or as liposomes for example, it has been found that a limiting factor of importance was the concomitant increase in the inherent toxicity of the cytotoxic drug, due to a significant change in its pharmacological distribution throughout the body. In fact, when confronted with such difficulties, those skilled in the art are left with barely any option, when it comes to treating in vivo cancer tumors which exhibit the phenomenon of multiple drug resistance (MDR). Quinine, which was recently proposed as an MDR inhibiting substance, is a perfect illustration of this situation and its use in human therapy is limited accordingly.
SUMMARY OF THE INVENTION
The invention has the merit of offering a solution which is both novel and particularly effective to the problem discussed above, inasmuch as it makes use of substances having a structure close to that of quinine. Surprisingly however, such substances proved to be more effective at a comparable dose and, at the same time, substantially less toxic than the currently proposed quinine. As was discussed above, the approach of using such alkaloids as substances inhibiting multiple drug resistance in anti-cancer therapy seemingly had little, if any, chance of achieving success.
The object of the invention is the use of cinchonine, of dihydrocinchonine or of hydroquinidine as substances inhibiting multiple drug resistance (MDR) in the treatment of cancer tumors with cytotoxic substances.
Another object of the invention is a pharmaceutical composition for use in the treatment of cancer tumors exhibiting the phenomenon of multiple drug resistance, which contains cinchonine, dihydrocinchonine or hydroquinidine as the substance inhibiting MDR.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphical illustration of the activity of certain antimitotic drugs when administered with varying amounts of cinchonine;
FIGS. 2A, 2B, 2C, and 2D are graphical illustrations of cell survival rate for four different cell rates when doxorubicin is administered with varying amounts of cinchonine or verapamil; and
FIG. 3 is a graphical illustration of the amount of intracellular radioactivity, indicative of intracytoplasmic doxorubicin, when doxorubicin was administered with varying amounts of cinchonine or quinine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Cinchonine and dihydrocinchonine are known substances belonging to the class of alkaloids, which have been suggested for use as therapeutic agents against malaria. As to hydroquinidine, the compound has been suggested as an antiarrhythmic agent. Both the pharmacology and the toxicity of these substances are known.
According to the invention, cinchonine, dihydrocinchonine and hydroquinidine can be advantageously used in the form of a pharmaceutical composition, dissolved in a medium suitable for parenteral administration, for example by subcutaneous or intramuscular injection or further in the form of a suspension or of tablets designed for oral administration. Further, cinchonine, dihydrocinchonine or hydroquinidine can be associated in such compositions with a particulate vehicle, such as microcapsules, microparticles, nanocapsules or nanoparticles. As an example of a particulate vehicle, one can advantageously use liposomes.
In such pharmaceutical compositions according to the invention, one can use as agent for inhibiting MDR, one of the above-mentioned substances as the only ingredient, such as for example einchonine; one can also use a mixture in various weight ratios of such substances, for example of ein- chonine and dihydrocinchonine.
Accordingly, a further object of the invention will be a pharmaceutical composition intended for the treatment of cancer tumors, containing as the agent for inhibiting MDR, one or several substances selected from cincho- nine, dihydrocinchonine and hydroquinidine.
Further, it is understood that such substances can be provided in the form of pure stereoisomers or of mixtures of such stereoisomers, or further of pure enantiomers or of mixtures or enantiomers. In the ease of cinchonine or of dihydrocinchonine for example, one can actually recognize different isomers, varying by their configuration at the C8 or C9 carbon.
According to the invention, substances such as cinchonine, dihydrocinchonine or hydroquinidine can be used concomitantly with other substances inhibiting MDR, and more particularly with substances the inhibitory activity of which has already been recognized. In this respect, one can mention, without being limited thereto, one or several known substances selected from amiodarone, quinine, quinidine, cinchonidine, verapamil, cyclosporin A, cephalosporins, biperiden, lidocaine, chlorpromazine, pentazocine, promethazine, potassium canrenoate, amitriptyline, propanolol, demethoxyverapamil, diltiazeme, thioridazine, trifluoperazine, chloroquine, sdbethylene diamine, reserpine, tamoxifen, toremifen, hydrocortisone, progesterone, salbutamol and their acylated derivatives or esters.
According to the invention, the desired inhibitory effect can be obtained with doses at which no adverse side effects are observed with the patients, which could be ascribed to the inherent toxicity of cinchonine, of dihydrocinchonine or of hydroquinidine. Clearly, the optimum therapeutic doses will depend upon the type of tumor being treated, the nature of the cytotoxic agent used concomitantly, the patient treated or other fur- ther factors, within the understanding of those versed in the art.
Cytotoxic substances which are affected by the MDR phenomenon and the effectiveness of which can be advantageously enhanced by the concomitant action of cinchonine, dihydrocinchonine or hydroquinidine are listed hereafter; this recitation is not, however, exhaustive.
They are mostly hydrophobic substances having in common a positively charged nitrogen residue, such as for example the Vinca alkaloids, anthracyclines or similar products, epipodophyllotoxins or anticancer antibiotics. One can mention in particular vincristine, vinblastine, vindesine, vinorelbine, doxorubicin, desoxydoxorubicin, tetrahydropyranyladriamycin, epidoxorubicin, aclacinomycin, demethoxydaunorubicin, daunorubicin, mamsa, mitoxanthrone, bisanthrene, demethoxydaunorubisanthrene, mithramycin, actinomycin D, puromycin, etoposide, tenoposide, emetine, ethidium bromide, cytochalasin, colchicine and taxol.
The invention has made it possible to propose a therapeutic treatment suitable for numerous cancer tumors exhibiting various levels of multiple resistance to anticancer agents (MDR). In this respect, one can mention, amongst others, acute myeloblastic leukaemia, acute lymphoblastic leukaemia, neuroblastoma, small cell lung cancer, ovary cancer, non-Hodgkin malignant lymphoma, diffuse plasmocytoma. These are cancers which can exhibit an induced MDR in response to a treatment with a cytotoxic agent.
One can also treat cancers exhibiting an innate MDR or at least cancer cells characterized by the presence, before any treatment, of the gene corresponding to P-gp (mdr 1) in a relatively high proportion. One can mention, for example, adenocarcinoma of the colon, adenocarcinoma of the kidney, cortico-adrenal carcinoma, pheochromocytoma, children's sarcoma, secondary leukaemia. This recitation is however not exhaustive.
EXAMPLES
The experiments described hereafter illustrate the present invention in a more detailed manner, without however limiting it.
a) Evidence of the inhibitory activity of cinchonine, in vitro
a.1. Aliquot portions, each containing 10'000 cells from the DHD/K12/TRb line ("drug resistant cell line"/MDR+), were distributed into series and implanted on slides, 48 hours before the treatment.
A first 60 minute incubation was carried out in HAMF 10 medium, supplemented with additives as follows:
control: - - -
series 0: doxorubicin (DXR) at 10 μg/ml
series 1: DXR (10 μg/ml)+cinchonine (5 μg/ml)
series 2: DXR (10 μg/ml)+quinine (5 μg/ml)
series 3: DXR (10 μg/ml)+verapamil (5 μg/ml)
Series 2 and 3 are used for comparative purposes, since they use substances known to inhibit MDR. A second 75 minute incubation was carried out subsequently in HAMF 10 medium complemented with a renewed portion of the inhibitory substance (series 1 to 3). The semi-quantitative evaluation of the presence of DXR in the cytoplasm of the treated cells was carried out using fluorescence microscopy (double-blind reading) to yield the following results:
______________________________________control: 0 series 0: 0series 1: +++ series 2: +++series 3: +++______________________________________ 0 = no fluorescence + = arbitrary unit of fluorescence
It can thus be seen that cinchonine has an inhibitory effect against MDR. This effect is comparable to that found with quinine and verapamil.
a.2. A similar experiment was carried out using aliquot portions each containing 10'000 DHD/K12/ TRb cells, implanted 24 hours before the treatment.
Actual treatment: 72 hour incubation in HAMF 10 medium +10% SVF, in the presence or not of cinchonine, As to the cytotoxic agents, the following ones were used, respectively, at the same concentration: etoposide (VP 16), vincristine. vindesine, mitoxanthrone (MXN) and doxorubicin. Conversely, the cinchonine concentration was varied as follows:
0-0.1-1-5-10 μmol
The survival rates of the implanted cells were evaluated using the blue dye method and converted into % activity of the antimitotic drug. The results obtained are summarized in FIG. 1. They confirm that cinchonine exerts an important inhibitory activity against MDR and enhances the cytotoxic activity of the antimitotic agent being used.
a.3. An experiment similar to the previous one was carried out to check the inhibitory activity of cinchonine, on other colon tumor cell lines in which the product of the expression of the mdr-1 gene and the expression of P-gp 180 had been clearly established.
The selected cells were implanted 24 hours before the treatment, in the proportion of 10'000 cells per well. The actual treatment consists in a 72 hour incubation, in the presence of doxorubicin (DXR) at the same concentration and of the following increasing mounts of cinchonine or verapamil:
0-1-5-10-20-40 μmol
The cell survival rates were determined by means of the blue dye method and the corresponding results are summarized in FIG. 2. The cell lines used were the following:
CACO2-HCT15-SW480-PR0b(DHD/K12/TRb)
The results shown in FIG. 2 are the averages of three determinations. They clearly confirm the inhibitory activity of cinchonine.
b) Evidence of the inhibitory activity of hydroquinidine, in vitro
Aliquot portions, each containing 100'000 cells of the DHD/K12/TRb line ("drug resistant cell line"/MDR+), were distributed in series and implanted on slides 24 hours before the treatment indicated hereafter, the cytotoxic agent being doxorubicin (DXK) containing 3% DXR 14C.
control: - - -
series 0: doxorubicin (DXR) at 10 μg/ml
series 1; DXR (10 μg/ml)+hydroquinidine (15 μg/ml)
series 2: DXR (10 μg/ml)+quinine (15 μμg/ml)
series 3: DXR (10 μg/ml)+verapamil (15 μg/ml)
Series 2 and 3 are used for comparative purposes, since they use substances which are known to inhibit MDR. After a two hour incubation, Followed by three successive two hour washings with PBS-BSA, trypsinization and cell counting, the intracellular radioactivity was measured using a β-ray counter.
The amount of intracytoplasmic doxorubicin directly associated with the inhibitory effect of the tested substance was deduced from these measurements. The results are summarized hereafter:
______________________________________Series N° Agent Radioactivity______________________________________0 DXR only 200 cpm1 DXR + hydroquinidine 875 cpm2 DXR + quinine 850 cpm3 DXR + verapamil 1050 cpm______________________________________
It can thus be seen, that hydroquinidine exerts a significant inhibitory effect on MDR. This effect is at least comparable to that found with quinine.
c) Evidence of the inhibitory activity of cinchonine, ex vivo
c.1. Each one of the two following inhibitory substances was administered by intravenous injection to rats, in groups of three, at their maximum nontoxic doses:
cinchonine: 50 mg/kg (1)
quinine: 40 mg/kg (2)
One hour after the IV injection, samples of blood were drawn directly from the heart of each animal. The same treatment was applied to control rats, which had received no treatment.
c.2. Aliquot portions, each containing 10'000 DHD/K12/TRb cells (see
a.1), were implanted 48 hours before the actual treatments indicated hereafter, the cytotoxic agent being doxorubicin (DXR):
control: - - -
series 0: DXR (10 μg/ml)+serum of control rats
series 1: DXR (10 μg/ml)+serum of rats (1)
series 2: DXR (10 μg/ml)+serum rats (2)
After a first one hour incubation, 3 successive washings were carried out using HAMF 10, and then a second one hour incubation of the washed cells was carried out in the presence of only a renewed portion of corresponding serum. The semi-quantitative evaluation of the DXR retention by the treated cells was performed by fluorescence microscopy (double-blind reading), to yield the following results:
______________________________________control: 0 Series 0: 0series 1: +++ Series 2: ++______________________________________ 0 = absence of fluorescence + = arbitrary fluorescence unit
It can be seen that cinchonine is at least as effective in vivo for inhibiting MDP, as quinine is.
d) Evidence of the inhibitory activity of hydroquinidine, ex vivo
d.1. The two following inhibitory substances were administered by intraperitoneal injection to rats, in groups of three, in the following doses:
hydroquinidine: 75 mg/kg (1)
quinine: 75 mg/kg (2)
One hour after the IP injection, blood samples were drawn directly from the heart of each animal. The same treatment was applied to the control rats, which had received no treatment.
d.2. Aliquot portions, each containing 100'000 DHD/K12/TRb cells (see a.1), were implanted 24 hours before the actual treatment, as indicated hereafter, the cytotoxic agent being doxorubicin (DXR) containing 3% DXR 14C.
control: - - -
series 0: DXR (15 μg/ml)+serum of control rats
series 1: DXR (15 μg/ml)+serum of rats (1)
series 2: DXR (15 μg/rnl)+serum of rats (2)
After two hours of incubation followed by three successive washings using PBS-BSA, trypsinization and cell counting, the intracellular radioactivity was measured using a β-ray counter.
The amount of intracytoplasmic doxorubicin directly associated with the inhibitory effect of the tested substance was deduced from these measurements. The results are summarized below:
______________________________________Series N° Agent Radioactivity______________________________________0 DXR only 250 cpm1 DXR + hydroquinidine 750 cpm2 DXR + quinine 500 cpm______________________________________
It can be seen that for a same serum concentration of the inhibitory substance, the intracytoplasmic DXR level in series 1 (DXR+hydroquinidine) is 3 times higher than in series 0 (DXR only); also, this level is approximately 1.5 times higher than in series 2 (DXR+quinine).
e) Comparison of the potency of cinchonine as inhibitor, with that of quinine, in ex vivo experimentation
e.1. Each one of the three following inhibitory substances was administered by intraperitoneal injection to rats, in groups of three, in the following doses:
cinchonine: 75 mg/kg (1)
cinchonine: 100 mg/kg (2)
quinine: 75 mg/kg (3)
quinine: 100 mg/kg (4)*
One hour after the IP injection, blood samples were drawn directly from the heart of each animals. The same treatment was applied to the control rats, which had received no treatment.
e.2. Aliquot portions, each containing 100'000 DHD/K12/TRb cells (see a.1), were implanted 24 hours before the actual treatment in the presence of the cytotoxic agent (doxorubicin (DXR) containing 3% DXR 14C).
control: - - -
series 0: DXR (5 μg/ml)+serum of control rats
series 1: DXR (5 μg/ml)+serum of rats (1)
series 2: DXR (5 μg/ml)+serum of rats (2)
series 3: DXR (5 μg/ml)+serum of rats (3)
series 4: DXR (5 μg/ml)+serum of rats (4)
After two hours of incubation, followed by three successive washings using PBS-BSA, trypsinization and cell counting, the intracellular radioactivity was measured using a β-ray counter.
The amount of intracytoplasmic doxorubicin directly associated with the inhibitory effect of the tested substance was deduced from these measurements. The results are summarized in FIG. 3.
It can be seen that for a same serum concentration of the inhibitory substance, the intracytoplasmic DXR level in series 1 (DXR+cinchonine) is 6 times higher than in series 0 (DXR only); also, this level is approximately 2 times higher than in series 3 (DXR+quinine), even after a twofold or a fourfold dilution of the sera.
It can further be seen that cinchonine is clearly less toxic than quinine is: for an IP injection of 100 mg/kg, two animals out the three died after the quinine injection.
e.3. A similar experiment was carried out, but using a different cell line: K 562/ADM (myelogenous leukaemia cell line).
It was confirmed that in this case also, cinchonine exhibits a higher inhibitory activity than quinine does.
f) Comparison of the potency of cinchonine as inhibitor, with that of quinine, using an in vivo experimentation
1'000'000 DHD/K12/TRb cells were administered per rat by intraperitoneal injection at day 0, in order to induce a peritoneal carcinomatosis of colic origin, used as the experimental model.
On day 1, free doxorubicin (DXR) and an inhibitory substance were administered simultaneously by intraperitoneal injection using an aqueous 5% glucose solution, in the following amounts:
group I: DXR/quinine: 0.5 mg/kg of DXR and 80 mg/kg of quinine,
group 2: DXR/cinchonine: 0.5 mg/kg of DXR and 80 mg/kg of cinchonine
group 3: DXR (05 mg/kg)
group 4: control
Each group included 5 rats and they were sacrificed on day 27. After autopsy, the tumor nodules were weighed separately for each animal. The values given hereafter are the averages for the 5 animals of each group.
group 1: 0.2 g (±0.2)
group 2: 0.1 g (±0.1)
group 3: 4.8 g (±1.2)
group 4: 5.0 g (±1.2)
It can thus be seen, that quinine and cinchonine inhibit significantly the resistance of tumors treated by means of doxorubicin. At the same dose. cinchonine is more potent than quinine in this type of experimentation; an additional advantage is the lower toxicity of cinchonine as was shown above. | Cinchonine, dihydrocinchonine or hydroquinidine are used as multidrug resistance inhibiting substance in the treatment of cancerous tumors by the use of cytotoxic agents. Particularly, cinchonine, dihydrocinchonine or hydroquinidine are used in the preparation of pharmaceutical compositions used in the treatment of cancerous tumors developing the phenomenon of multidrug resistance. Application to the treatment of human cancers. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a device for marking objects by the vibrating tip of a pneumatic tool.
2. History of the Related Art
Marking devices in which the tip of a pneumatic tool is actuated by a compressed gas such as air, are known. Such devices move cyclically along their axis in the direction of the surface of the object to be marked. After some degree of movement the devices strike the object and then return to their initial position. Each impact causes aslight plastic deformation of the surface of an object. Known guiding means make it possible to displace the tip of marking devices in the vicinity of the surface of the object to be marked without interrupting the cyclic functioning of the tip at relatively high frequency. The vibrating tips may thus trace by micro-percussion, by their displacement along two perpendicular axes parallel to the plane of the surface of an object, identification markings such as letters, figures or other patterns.
Devices for guiding a pneumatic tool to effect such a marking by micro-percussion are also known. They comprise two carriages which move in perpendicular directions, each driven by a motor controlled by conventional electronics. Often, one of the two motors is mounted on one of the two carriages, which complicates its electrical supply. The two carriages must be guided individually with high precision in order to obtain sufficiently precise lines of the identification markings.
The possibility has been considered of making a device for marking by micro-percussion which does not comprise a double-carriage structure which allows the guiding of a pneumatic tool with vibrating tip with high precision so as to trace on the plane of marking of an object, two-dimensional identification markings. It is also desired to avoid mounting a drive motor on a movable carriage in order to simplify and lighten the carriage which drives the pneumatic tool.
The device forming the subject matter of the invention brings a particularly efficient solution to the problem raised.
SUMMARY OF THE INVENTION
The invention is directed to a device for marking by micro-percussion which comprises a pneumatic tool provided with a vibrating tip adapted to trace, on the plane of marking of an object, by plastic deformation, two-dimensional identification markings. A first drive member makes it possible, via a first transmission, to displace the pneumatic tool by appropriate guides along an axis of translation parallel to the plane of marking. A second drive member normally connected to a second transmission, makes it possible to rotate the tool about an axis, in a plane perpendicular to the axis of translation in order to displace the points of impact of the vibrating tip on the plane of marking in a direction perpendicular to the direction of translation. In a work position, the radius R of the circle tangential to the plane of marking of the object, having for its center the axis of rotation of the tool, is greater than 1.5 times the extent of the zone of marking on the plane of the object in a direction perpendicular to the axis of translation. Under these conditions, the angular opening of the arc of a circle which may be covered by the vibrating tip of the pneumatic tool in the zone of a marking does not exceed 40°.
The angular opening of the arc of circle which may be covered by the vibrating tip to attain the whole extent of the zone of marking is preferably less than 30° and the radius R is greater than twice the extent of the marking zone.
The means for guiding the pneumatic tool along the axis of translation is preferably a shaft on which a carriage which supports the pneumatic tool is slidably mounted.
Also, the first transmission means is preferably a synchronous belt or chain, disposed parallel to the axis of translation, driven by a pinion connected to the first drive, member and connected at a point, directly or indirectly, to the pneumatic tool.
The axis of rotation of the pneumatic tool should also merge with the axis of the shaft on which the carriage is slidably mounted.
The second transmission includes a rod connected to the second drive member by a crank which, by an appropriate linkage, drives the pneumatic tool about its axis of rotation so as to displace the vibrating tip inside the arc of a circle corresponding to the extent of the marking zone. In another embodiment, a transmission system of the belt and pulley type may be employed, which performs the same functions as the connecting rod/crank assembly, while allowing a greater angular stroke to facilitate replacement of the marking stylus.
Preferably, the synchronous belt or chain is connected to the pneumatic tool via a piece comprising a bore of revolution, mounted to rotate freely on a shaft which guides the tool in translation, the two lateral faces of this piece being separated by a small clearance of the lateral walls secured to the pneumatic tool; connection between the bored piece and the synchronous belt or the chain is ensured by a connecting rod. The lateral walls fast with the pneumatic tool against which the bored piece abuts are advantageously the lateral walls of a cut made in the tool-holder carriage for housing this bored piece between two bearing surfaces of this carriage on the guide shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawing describes, in non-limiting manner, a particular embodiment of the present invention.
FIG. 1 is a view in elevation of the invention taken in the direction of arrow F1 of FIG. 2.
FIG. 2 is a view in elevation of the invention of FIG. 1 taken in the direction of arrow F2 of FIG. 1.
FIG. 3 is a section taken along plane A--A of FIG. 2.
FIG. 4 is a section taken along plane B--B of FIG. 2.
FIG. 5 is a view in elevation, similar to that of FIG. 2, but corresponding to a variant embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The device shown in FIGS. 1 to 4 comprises a carriage 1 to which is fixed a pneumatic tool 2 provided with a vibrating tip 3 adapted to move along its axis x1 in a cyclic reciprocating movement under the action of a compressed gas such as air. The carriage 1 is mounted to slide on a shaft 4 which guides the carriage along the axis of translation x2--x2. The carriage includes two bearing surfaces 5, 6 between which a cylindrical piece 7 is mounted to rotate freely on the shaft 4. The lateral annular faces of the piece 7 are separated by a small clearance 7A from the corresponding lateral faces of the bearing surfaces 5, 6; the small clearance such as 7A allows free rotation of the bearing surfaces with respect to the cylindrical piece 7 which is connected to a synchronous belt 8 by a connecting rod 9. The synchronous belt 8 which functions as a first transmission is stretched parallel to axis x2--x2 between the pinion 10 of a first drive motor 11 and a guide pulley 12. The connecting rod 9 is fastened to the belt 8 by a clamping tab 13. The shaft 4, free to rotate in bearing surfaces 14, 15, at its two ends, is connected by two parallel small rods 16, 17 which are blocked from rotation with respect to shaft 4 and also with respect to a secondary shaft 18 parallel to the shaft 4. Carriage 1 abuts the secondary shaft via a sliding bearing surface 19.
The second drive motor, via a second transmission, provokes rotation of carriage 1 about x2--x2. As shown in the Figures, this second transmission comprises a crank 21, driven by the second drive motor 20, which drives a connecting rod 22 connected to the secondary shaft 18 that it rotates about shaft 4, causing rotation of carriage 1. It will be noted that, whatever the position of the carriage 1 along the shaft 4, the same displacement of the connecting rod 22 brings about rotation of the carriage 1 through the same angle and therefore the same angular displacement of the vibrating tip 3.
As shown in FIG. 1, the extent of the marking zone of the vibrating tip 3 on the plane of marking 23 of an object corresponds to an arc 24 of about 20°. It will be noted that the radius R of the circle of axis x2--x2 tangential to the plane of marking of an object with the vibrating tip 3 being in working position with respect to plane 23, is equal to about 3 times the extent of this marking zone corresponding to the arc of 20°. It will be observed that, under these conditions, the stroke of the vibrating tip is increased only by a length of 1.5% of radius R at the two ends of the arc, spaced apart only by 10° with respect to the vertical axis x1. In practice, it is observed that the slight variation of stroke of the vibrating tip before the impact, and the slight difference with respect to the vertical do not bring about any appreciable variations in the effects of the impact. The line conserves the necessary sharpness for making identification markings.
Furthermore, it should be noted that the two drives 11, 20 are step-by-step motors, controlled by pulses from electronic pulse-generator means (not shown) well known to the man skilled in the art. These two motors are mounted on a plate 25 fixed with respect to the carriage 1. The inertia of the carriage is therefore reduced to a minimum and its only connection with a source of energy is a supple pipe (not shown) for supply of a compressed gas such as air; the supple pipe is connected to the orifice 26 of the pneumatic tool.
The embodiment of the device according to the invention may form the subject matter of numerous variants or adaptations. In particular, the transmission means between the motors and the mechanisms that they control may undergo numerous modifications. In this way, the synchronous belt 8 may be replaced by a chain. Similarly, the transmission by connecting rod 22 and crank 21 of the moment of the second drive means 20 may be replaced by a direct drive of the shaft 4, the motor being placed at the shaft end with a suitable reduction ratio.
The variant embodiment illustrated in FIG. 5 may also be adopted where the connecting rod/crank system 21-22 is replaced by a belt 27 stretched between two pulleys of which one, 28, is fitted on the shaft of the motor 20 while the other, 29, is secured with the secondary shaft 18. Consequently, angular displacement of the tip or stylus 3 is obtained and, in addition, in order to facilitate replacement thereof, the assembly may be raised up to the position indicated at H in FIG. 1. | A device for marking objects by micro-percussion pneumatic tools including a vibrating tip wherein the tools are mounted on a carriage which is slidably mounted with respect to two support shafts and which is moved along an axis of translation by a first drive member and wherein the carriage is pivotally mounted to swing the tip of the tool in a direction perpendicular to the direction of translation by a second drive member. | 1 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Ser. No. 61/947,032 filed Mar. 3, 2014 entitled Fluid Delivery Damping and Delivery Pump, which is hereby incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Insulin pumps are medical devices used for the administration of insulin in the treatment of diabetes, which is known as continuous subcutaneous insulin infusion therapy. Typically, insulin pumps include a pump mechanism, a disposable reservoir for insulin, and a disposable infusion set (e.g., a cannula for insertion under the user's skin).
[0003] In an attempt to increase battery efficiency and safety, a variety of different pump mechanisms have been contemplated in battery powered insulin pumps. For example, such pump mechanism include servomotors with gear trains; nitinol wires that deform when electrically stimulated; heated wax that changes volume or actuates a check valve, and MEMS valves whose diaphragm motion open and close check valves. These methods however typically require complex, large, and expensive mechanical arrangements, as well as having substantial power consumption, requiring a large battery and/or frequent recharging.
SUMMARY OF THE INVENTION
[0004] In one aspect of the present invention, a pump controllably moves a small quantity of fluid from a fluid chamber to an outlet port with a small inexpensive actuator powered for a very short amount of time, thereby optimizing cost, size, and battery efficiency.
[0005] In another aspect of the present invention, the pump includes a fail-safe position such that component failure will not result in free flow between the fluid chamber and the patient.
[0006] Another aspect of the present invention includes a method of pumping a fluid in which a pulse of a device such as an electrical solenoid pushes on a piston to controllably move a small quantity of fluid by hydraulically filling a pressurized delivery chamber. The delivery chamber slowly dispenses the fluid by adding a restriction to the flow out of the outlet port to dampen the fluid flow rate between actuations to prevent sudden spikes of liquid.
[0007] Another aspect of the present invention includes a pump enclosure having multiple pump mechanisms, which can each be configured to pump a different drug to a patient.
[0008] Yet another aspect of the present invention includes a method of delivering different drugs to a patient from a single pump enclosure.
[0009] Yet another aspect of the present invention includes measuring sensor data from within an air chamber open to the atmosphere within a pump enclosure and determining a volume of fluid remaining in a fluid chamber.
[0010] Another aspect of the present invention includes calibrating a pump enclosure for measuring an accurate volume of fluid in a fluid chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other aspects, features and advantages of which embodiments of the invention are capable of will be apparent and elucidated from the following description of embodiments of the present invention, reference being made to the accompanying drawings, in which
[0012] FIGS. 1A-5 illustrate one embodiment of a fluid pump according to the present invention.
[0013] FIGS. 6A-11B illustrate another embodiment of a fluid pump according to the present invention.
[0014] FIGS. 12A-16B illustrate another embodiment of a fluid pump according to the present invention.
[0015] FIGS. 17-26 illustrate an embodiment of a pump enclosure having multiple fluid chambers and pumps.
[0016] FIGS. 26-30 illustrate various options of materials within fluid chambers of the pump enclosure according to FIGS. 17-26 .
[0017] FIG. 31 illustrates a feedback system for a pump enclosure.
[0018] FIG. 32 illustrates an example pressure measurement from the feedback system in FIG. 31 .
[0019] FIG. 33 illustrates a flow chart of a method for determining a liquid volume via the feedback system of FIG. 31 .
DESCRIPTION OF EMBODIMENTS
[0020] Specific embodiments of the invention will now be described with reference to the accompanying drawings. This invention may, however, be embodied 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 fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements.
Pump Mechanism and Operation
[0021] One aspect of the present invention is directed to a pump mechanism and method of use. Specifically, a displacement mechanism is used deliver small quantities of fluid (e.g., insulin) to a patient or to another pumping application. While the present specification primarily describes a solenoid as the displacement mechanism, it should be understood that a number of other devices can also be used, such as a motor, electromagnet, cam actuators, ultrasonic motors, magnets with shielding, Nitinol wire phase change materials, expanding/contracting materials, or similar devices.
[0022] FIGS. 1A-5 discloses one embodiment of a pump mechanism 100 that is actuated by a solenoid 106 . When the solenoid 106 is operated, fluid (e.g., insulin) from a fluid chamber 112 is pumped into the input port 104 A, through input lumen 104 , and ultimately out the output port 116 .
[0023] The solenoid 106 is preferably located within a chamber of a pump housing 102 and, when activated, moves a plunger 108 against a compressible elastomer film or flexible sheet 110 . The film 110 is preferably connected around or near its outer edges and is fitted to have slack (i.e., is not pulled tight), allowing the film 110 to deform or bend. In this respect, when the plunger 108 is extended (i.e., moved to the left), the film 110 is pressed against an end port 104 B of the input passage 104 , closing off the port 104 B and preventing any further liquid to enter the pump 100 .
[0024] The pump 100 also includes a delivery piston 118 that moves laterally between a larger diameter pump chamber 102 A and a smaller diameter pump chamber 102 B (seen best in FIG. 1B ). The delivery piston 118 includes a cylindrical portion 118 A which has diameter that is slightly smaller than the chamber 102 B, allowing the cylindrical portion 118 A to slide within the chamber 102 B. A disk portion 118 C is connected to the cylindrical portion by an elongated connection portion 118 B, and has a diameter that is slightly smaller than the chamber 102 A.
[0025] The piston 118 is biased towards the solenoid 106 by a spring 114 . The spring 114 is preferably connected to the cylindrical portion 118 A and to a location left of the piston, such as the septum 113 or to the wall of the chamber 102 B. Since the fast action of the on/off cycle of a solenoid 106 (or similar actuator mechanism) can delivery fluid faster than the patient's tissue can absorb, creates sheer forces on the fluid molecules (e.g., insulin) potentially disrupting their efficacy, and can potentially injure the patient at the injection site, the spring helps dampen the solenoid force. Specifically, as the solenoid causes the delivery piston 118 to move to the left, the spring 114 helps reduce the speed of the piston 118 to create a more gentle movement, as well as stores some of the energy create by the solenoid 106 . While a spring 114 is described, it should be understood that a variety of different dampening mechanisms are possible, such as magnetic dampening mechanisms and elastomeric members.
[0026] To allow movement of the delivery piston 118 and injection of fluid via the septum 113 , the smaller diameter pump chamber 102 B includes one or more fluid return ports 103 (e.g., 3 or 6 ports), which connect the pump chamber 102 B with the fluid chamber 112 .
[0027] With regard to the operation of the pump 100 , FIGS. 1A and 1B illustrates the pump in a neutral position in which the delivery position 118 covers the entrance 116 A to the output port 116 .
[0028] Turning to FIG. 2 , power is applied to the solenoid 106 , causing the plunger 108 move to the right, against the plunger return spring 107 . The delivery plunger 118 also moves to the right, maintaining the output port 116 in a blocked or closed configuration and pressing against the film 110 so as to open the input lumen 104 . In this respect, fluid from the fluid chamber 112 passes into input port 104 A, along input passage 104 , out the end port 104 B, and into the larger diameter chamber 102 A.
[0029] Once the larger diameter chamber 102 A has filled with fluid, the solenoid 106 is powered off, allowing the plunger release spring 107 to begin moving fluid towards the left of the pump 100 , thereby causing the fluid to move the piston 118 to the left, as seen in FIG. 3 . As such, the end port 104 B becomes covered or blocked by the film 110 , preventing further passage of fluid through the input passage into the chamber 102 A.
[0030] As seen in FIG. 4A , the continued movement of the plunger 108 to the left against the film 110 , causing the fluid in the chamber 102 A to press against the displacement piston 118 , moving the piston 118 further to the left. At this position, the cylindrical portion 118 A no longer blocks the output port 116 and a portion of the fluid in the smaller diameter chamber 102 B (e.g., portion 102 C in FIG. 4B ). In other words, the entire contents of both chambers 102 A and 102 B do not empty out of the output port 116 ; instead only a fraction of that fluid is displaced. Additionally, the piston 118 has compressed against the spring 114 , storing some of the energy imparted via the solenoid 106 and displacing some of the fluid on the left side of the piston 118 out the fluid return ports 103 .
[0031] It should be understood that the amount and rate of fluid leaving the chamber 102 B in this position can be controlled by a number of factors. For example, the diameter and length of the output port 116 can both be increased or decreased to adjust an amount and/or rate of displaced fluid per cycle. Other factors may also influence this, such as the compressibility of the springs 114 and 107 , the size of the chambers 102 A and 102 B, the diameter holding the fluid in the film, and the strength and actuation time/speed of the solenoid 106 .
[0032] Referring to FIG. 5 , with a portion of the fluid displaced, the spring 114 begins to push back the piston 118 , closing the output port 116 and returning to a neutral (i.e., nonmoving position). In this position, both the output port 116 and the end port 104 of the input passage 104 are closed. In this respect, if the solenoid 106 or other components controlling the solenoid 106 break, or if the piston sticks, the pump will not allow constant flow of insulin through the pump 100 and into the patient.
[0033] FIGS. 6A-11B illustrate another embodiment of a pump 130 that is constructed and operates in a generally similar manner to the previously described pump 100 . However, instead of single piston and a film, the present pump 130 includes a solid, cylindrical delivery piston 132 , a tubular fill piston 134 , and a cylindrical refill piston 136 .
[0034] The cylindrical delivery piston 132 is preferably sized slightly smaller in diameter than smaller diameter chamber 102 B and moves laterally to selectively block the output port 116 . The tubular fill piston 134 is sized slightly smaller in diameter than the larger chamber 102 A and moves laterally to selectively open and close the input passage 104 . The tubular fill piston 134 also includes a passage therethrough in which the cylindrical refill piston 136 slides during operation, creating a small refill chamber.
[0035] FIGS. 6A and 6B illustrate the pump 130 in a neutral position in which neither the solenoid 106 , nor the spring 114 are actively creating motion of the components within the pump 130 . The delivery piston 132 can be seen closing off the delivery port 116 , preventing fluid from passing to the patient. The fill piston 134 can be seen moved to the right, allowing fluid to enter from the input passage into the area around the delivery piston 132 within the larger chamber 102 A.
[0036] In FIGS. 7A and 7B , the solenoid 106 is actuated (i.e., power is applied), causing the plunger 108 to move to the left. As the plunger moves 108 , pressure builds within the chamber 102 A, causing the refill piston 136 to push back, to the right. As the fill piston 134 continues to move to the left, it closes of the input port 104 , creating a small, somewhat pressurized chamber of fluid within the fill piston 134 .
[0037] As seen in FIGS. 8A and 8B , the plunger 108 continues to move left, moving with it the fill piston 134 , the refill piston 136 and the delivery piston 132 . In this position, the delivery piston 132 has moved far enough to the right so as to open output port 116 , thereby allowing some of the fluid to be discharged from the pump 130 .
[0038] In FIGS. 9A and 9B , the power to the solenoid 106 is turned off so that the plunger 108 no longer applies leftward pressure. With reduced fluid in the pump chambers and a lack of force from the plunger 108 , the compressed spring 114 pushes the delivery piston 132 rightward, thereby blocking off the delivery port 116 .
[0039] In FIGS. 10A and 10B , the delivery piston 132 continues to move to the right, contacting and pushing the fill piston 134 . As seen best in FIG. 10B , the delivery piston 132 and fill piston 134 stop their movement as a hydraulic lock point is created by the chamber formed at location 135 . This hydraulic lock point is eliminated as fluid from within the chamber within the fill piston 134 migrates into area 135 (e.g., via a small gap formed between the right side of the delivery piston 132 and the left side of the fill piston 132 ). As the fluid moves to area 135 , the refill piston 136 moves further to the left while the delivery piston 132 and fill piston 134 move to the right, as seen in FIGS. 11A and 11B . Eventually, the fill piston 134 moves far enough to the right to open the input passage 104 and the pump cycle can begin again.
[0040] FIGS. 12-16 illustrate another embodiment of a pump 140 according to the present invention. The pump 140 is generally similar to the previously described pumps 100 and 130 . However, the pump 140 includes an elastomeric fill sleeve 144 disposed around the fill piston 142 , selectively opening and closing the input passage 104 during operation.
[0041] In FIG. 12A , the solenoid 106 remains unactuated (i.e., no power is applied) and the plunger 108 is fully retracted to the right. The delivery piston 132 is positioned to block the output port 116 and the fill piston is positioned against the plunger 108 and the delivery piston 132 . As described below, during a normal cycle, hydraulic lock pressure is created in the chamber formed between the delivery piston 132 and the elastomeric fill sleeve 144 . This force pulls the elastomeric sleeve 144 away from a bypass channel 141 (seen in FIG. 12B ) that connects between the input passage 104 and the larger diameter chamber 102 A, thereby opening the input passage 104 and allowing fluid to be sucked into the pump 140 .
[0042] In FIG. 13A , fluid has entered the chamber 102 A. As the solenoid 106 is actuated, the plunger begins to exert pressure on the fill piston 142 and thereby create pressure within the chamber 102 A. As seen in FIG. 13B , this pressure pushes the elastomeric sleeve upwards into the bypass channel 141 , filling the channel 141 and closing of the input passage 104 .
[0043] In FIG. 14 , the plunger 108 moves further to the left, increasing pressure within the chambers 102 A and 102 B. This increased pressure causes the delivery piston 132 to slide to the left, past the output port 116 , causing a portion of the fluid in the pump 140 to be expelled.
[0044] As the fluid leaves the chamber 102 B, the pressure in the chamber 102 B reduces. Additionally, the power to the solenoid 106 is deactivated, allowing the compressed spring 114 to push the delivery piston 132 back to the right, closing the output port 116 as seen in FIG. 15 .
[0045] As seen in FIGS. 16A and 16B , as the delivery piston 132 continues to move to the right, an area 143 is created between the delivery piston 132 and the elastomeric sleeve 144 , creating a hydraulic lock. The force of the hydraulic lock pulls downward on the elastomeric sleeve 144 , away from the channel 141 , pulling additional fluid into the chamber 102 A. This ultimately results in the configuration seen in 13 A and allows the pump cycle to be repeated.
Pump Enclosure with Multiple Chambers
[0046] In another embodiment according to the present invention, FIGS. 17-26 illustrate various aspects of a pump enclosure 150 having multiple chambers to accommodate multiple pumps. While this embodiment of the pump enclosure 150 accommodates up to 4 fluid pumps, it should be understood that the enclosure could also be configured for different numbers of pumps, such as 2, 3, 5, and 6. Any of the pumps previously described in this specification (or variations thereof) lend themselves particularly well to use in the present pump enclosure 150 , due to the relatively small size of the pumps and the relatively low power consumption afforded by the solenoid 106 (or similar actuator mechanism).
[0047] FIG. 17 illustrates the pump enclosure 150 , having a lower housing member 154 , an upper housing cover 152 , a cannula 156 (or rigid needle), and a plurality of septums 113 from each of the pumps within the enclosure 150 . FIG. 18 illustrates the enclosure 150 with the upper housing cover 152 removed, exposing a top sealing cover or film 164 , a plurality of solenoids 106 that drive each of the pumps, a battery 158 , and a circuit assembly 160 comprising a plurality of electrical components that control and operate the enclosure 150 .
[0048] FIG. 19 illustrates a similar view of the enclosure 150 as the prior figure, except that the film 164 has been removed to expose four pump chambers 166 . Each chamber 166 includes pump housings 165 (also seen in FIG. 21 ) that are similarly shaped to those of the pump housing 102 , as described in previously described pump embodiments. In this regard, the pump components shown in FIG. 20 (e.g., the septum 113 , spring 114 , and chambers 102 A, 102 B) are located within passage created within each housing 165 .
[0049] In one embodiment, the walls of the chambers 166 and the film 164 create the fluid chamber (e.g., fluid chamber 112 ). Alternately, a flexible bag or container can be located within the each chamber 166 to act as the fluid chamber.
[0050] The output ports 116 of each of the pumps are connected to apertures 172 in the lower housing member 154 , as seen best in FIGS. 23-25 . These apertures 172 each connect to a channel 176 on the lower side of the housing member 154 that connects to a single aperture 174 . These channels 176 can be formed into a sealed passage system with a lower plate or film 162 fixed over both the channels 176 and the aperture 174 , as seen in FIG. 22 . As best seen in FIGS. 25 and 26 , the aperture 177 connects with a curved septum passage 168 , which allows the cannula 156 (or rigid needle) to connect with the pump enclosure and receive the fluid from any/all of the pumps.
[0051] In an alternate embodiment, the output port of one or more of the pumps can be directly connected to a fluid chamber of an adjacent pump, allowing the contents of one fluid chamber to be delivered to the fluid chamber of another pump.
[0052] It should be understood that the circuit assembly 160 includes a variety of circuitry to operate the pumps of the controller, as well as any other electrical components that may be present. For example, the circuit assembly 160 may include a microprocessor or microcontroller, a memory, software stored in the memory and executed by the microprocessor/microcontroller, sensors (e.g., pressure sensor, temperature sensor), and a communications port.
[0053] It should be understood that a variety of different drugs and combinations of drugs are possible for each of the fluid chambers of the pump enclosure 150 . Several enclosure examples and methods of use are discussed below, however, each of these drugs can be mixed and matched in many different configurations, all of which are contemplated in the present invention.
[0054] In one embodiment, multiple fluid chambers may have two or more types of insulin with different pharma kinetic actions. In one example seen in FIG. 26 , at least one fluid chamber of the enclosure may contain a fast acting insulin 180 , such as lispro, aspart, and glulisine, and another chamber may contain a slow acting insulin 182 , such as insulin glargine or insulin detemir. In another example seen in FIG. 27 , an intermediate acting insulin may also be included in another chamber of the enclosure 150 , such as NPH.
[0055] Emergency rescue pens are used by diabetics when their glucose goes low and they begin to show signs of hypoglycemia. These pens combine liquid and lyophilized powder to form a glucagon fluid that is stable for about 24 hours. Typically, all of the fluid is immediately used.
[0056] Another configuration of the enclosure 150 can combine the functionality of such an emergency rescue pens with typical insulin pump functionality. For example, FIG. 28 illustrates a first chamber containing insulin 186 for normal insulin pump operation, a lyophilized powder 188 in a second chamber, a diluent 190 in a third chamber, and saline 192 in a fourth chamber. The output port of the third pump can be configured to lead only to the second chamber, allowing the third chamber's pump to move into the second chamber with the lyophilized powder to create glucagon. The second chamber's pump can then be activated to output glucagon to the patient. Finally, the saline 192 of the fourth chamber can be used to rinse the cannula/needle of any glucagon residue.
[0057] FIG. 29 illustrates a similar example to that of FIG. 28 , except that instead of mixing both a powder and diluent, a liquid stable glucagon is used in a second chamber.
[0058] FIG. 30 illustrates another configuration of the enclosure 150 in which amylin 196 is included in one of the chambers to slow post prandial emptying to better regulate the speed of insulin activation and thereby better match glucose uptake.
[0059] As mentioned above, a pump enclosure may include one or more, or even all of the following in different fluid chambers of the enclosure: Fast acting insulin, slow acting insulin, intermediate acting insulin, lyophilized powder, diluent, saline, liquid stable glucagon, and/or amylin. Again, the saline can be used to flush the channels of the enclosure and the cannula/needle to remove any residual drugs and prevent an inadvertent mixing during delivery.
[0060] In another embodiment of the present invention, one of the pumps of the pump enclosure 150 can be configured for measuring glucose. Specifically, one pump is configured to move fluid from the cannula 156 to a testing chamber in the pump. Unlike traditional CGMS needles that require a separate stick, by waiting between interstitial drug dosages, the interstitial fluid washes through the drug. During this time, a small amount of fluid inside the cannula and outside the cannula could be drawn in to test the level of glucose at the site and correlate it back to a blood plasma glucose level. Furthermore, the cannula could have the glucose oxidase inside of it with electrodes to measure within the cannula.
[0061] In another aspect of the present invention, the enclosure 150 includes a plurality of indicators 151 , such as LED lights, that correspond to and are located near a specific pump and septum 113 within the enclosure 150 . In this respect, activation of the indicator 151 may be used to indicate a status of a pump. For example, the indicator 151 may indicate that a fluid reservoir is empty or that a pump has become broken. The indicator 151 may be capable of illuminating a single color or multiple colors, each of which indicate a different status (e.g., green means operational, yellow means empty fluid reservoir, and red means a broken pump).
[0062] In another aspect of the present invention, the enclosure may include a single indicator 151 that illuminates in several different colors that each correspond to a color of a septum 113 . For example, the first septum 113 may be green and the second may be blue. When the indicator 151 illuminates in either of these colors, the user is made aware that the fluid reservoir for that pump is empty and therefore requires filling. Alternately, each septum 113 could have a different shape (e.g., circle, square, triangle), number, or other indicator, and a display on the enclosure may also display these indicators as necessary to indicate empty fluid reservoirs.
Pump Feedback
[0063] One further benefit of the pump embodiments and pump enclosure embodiments of the present invention is that they can allow various aspects of pump cycles to be measured, so as to allow onboard circuitry to determine if the pump mechanism is operating properly. For example, with certain measurements, pump enclosure circuitry may determine if the pump mechanism is delivering the proper or expected quantity of fluid.
[0064] FIG. 31 illustrates an embodiment of a pump enclosure 200 having a pressure sensor 202 , a temperature sensor 204 , and a gas restrictor 206 , all of which are either located in or are in communication with a gas or air chamber 208 . As the pump 140 operates, it increases and decreases the amount of fluid in its flexible fluid chamber 112 . For example, the pump 140 may initially increase the amount of fluid in the fluid chamber 112 during its filling portion of its cycle and then decrease the amount of fluid during delivery of the fluid to the patient. These increases and decreases in volume of the fluid within the air chamber 208 of the enclosure 200 increase or decrease the air pressure within the air chamber 208 (e.g., as seen in FIG. 32 ).
[0065] By measuring the pressure and temperature of the air/gas within the air chamber 208 , the enclosure's onboard circuitry can determine the volume of the air chamber 208 that is not occupied by the fluid chamber 112 with Boyle's Law. This volume can be subtracted from the known volume of the air chamber 208 with an empty fluid chamber 112 to determine the fluid volume.
[0066] If the air chamber 208 was completely sealed, a vacuum could be created within the chamber 208 as fluid is pumped out of the fluid chamber 112 . Since such a vacuum could ultimately hinder operation of the pump 140 , an air restrictor 206 can be used to slowly vent and thereby slowly equalize the air chamber 208 with the atmosphere. The previously described fluid volume calculations can still be performed by also compensating for the resistance to airflow through the restrictor 206 using Poiseuille's Law. Poiseuille's Law of fluid flow determines the amount of fluid that passes through a restriction as a function of the viscosity, pressure differences, size of the restriction and length. By adding a restriction of known physical characteristics and measuring the pressure on one side (and knowing the pressure on the other side by measuring it during static conditions), the changes in the gas and liquid volume can be measured and determined dynamically.
[0067] These measurements and calculations by the onboard circuitry/software could identify how quickly the actuator (e.g., solenoid 106 ) is moving the pump elements, how far the delivery piston has moved due to the displacement of fluid, how much fluid has returned to the fluid chamber when the motion begins at the neutral position and the rate of flow from the delivery chamber to the output. This occurs because there are two functions at work, the displacement of fluid out of the delivery chamber and the flow of gas through the restriction due to the pressure differentials.
[0068] In this respect, the present invention contemplates a method of a pump enclosure measuring pressure and temperature within an air chamber 208 (step 210 ), compensating for airflow through a restrictor 206 connected to the air chamber 208 (step 212 ), and determining a volume of fluid in a fluid chamber 112 (step 214 ), as seen in FIG. 33 .
[0069] The restrictor 206 can be made of rigid materials, such as, rubies, diamonds, glass, plastic, and other materials commonly used in the practice. The flow characteristics of the restrictor 206 can be characterized or calibrated during the initial pumps (by the onboard circuitry/software) when the volume in the fluid chamber 112 is known and the air chamber 208 is known. The enclosure may also be calibrated by performing volume calculations via the circuitry/software, injecting a known volume of liquid into the fluid chamber 206 , inputting the volume into an interface associated with the enclosure, performing a second volume measurement, and then comparing the difference between the injected amount and the calculated amount. In the case of either method, the changes in pressure can be used to determine the resistance caused by the restrictor 206 , accounting for variations in manufacturing and dirt or other changes that may change the behavior of the restrictor 206 over time.
[0070] Preferably, the restrictor 206 is sized small enough such that the small pressure created in the movements internally are insufficient to pull liquid into the air chamber 208 , due to the surface tension characteristics of the restrictor 206 . This may prevent water and other fluids from being sucked into the air chamber 208 during cleaning, showers, and swimming, for example.
[0071] It should be understood that by monitoring fluid volume in the fluid chamber 112 , a variety of different diagnostics and alerts are possible. For example, FIG. 34 illustrates a method of determining if a fluid pump is pumping an expected amount of fluid. First, a pump cycle is actuated as explained with regard to several of the different pump embodiments of the present specification (step 216 ). Next, the electronics and software of the pump enclosure 200 compare a calculated fluid volume of the fluid chamber 112 from before the previous pump cycle to a calculated fluid volume after the pump cycle (step 218 ). Finally, the electronics and software of the pump enclosure 200 determine if the expected fluid decrease matches the measured fluid decrease (step 220 ). If the two fluid volume decreased do not “match” (e.g., are not within 5% of each other), the electronics and software of the pump enclosure 200 may generate a warning (e.g., on an interface on the pump enclosure or a separate interface connected to the pump enclosure via a wired or wireless communications protocol).
[0072] While pressure measurement can be used to monitor pumping cycles, the pumping cycles could also be monitored by including a cycle counting sensor. For example, a Reid or Hall effect sensor could be used to monitor movement of various pistons in the pump. In this respect, the pump enclosure's electronics and software could alert the user when an expected pump fails to occur or when a greater number of pump cycles occur than expected.
[0073] In one aspect of the present invention, the pump enclosure 200 may include a multicolor light (e.g. a tricolor LED) that indicates the cycle of a pump within the pump enclosure. For example, a yellow light may indicate a pressure increases to an acceptable level, a green light may indicate that the pressure has dissipated due to deliver of the fluid, and a red light may indicate that an unexpected sensor/pressure/volume value.
[0074] Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof. | A pump controllably moves a small quantity of fluid from a fluid chamber to an outlet port with a small inexpensive actuator powered for a very short amount of time, thereby optimizing cost, size, and battery efficiency. Multiple pumps can be housed in a single enclosure, allowing multiple drugs to each be injected through a single cannula or needle. | 0 |
CROSS-REFERENCE TO RELATED PROVISIONAL APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Nos. 61/812,483 filed on Apr. 16, 2013, and 61/863,661 filed on Aug. 8, 2013, the disclosures of both of which are hereby incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention generally relates to devices, methods and systems for controlling the flushing of sanitaryware connected to a drainage system.
BACKGROUND OF THE INVENTION
[0003] Sanitaryware, such as toilets and urinals, and the pipes they connect to, deliver waste from within a structure (e.g., a commercial building or a residence) to sewer or septic systems. Applicable plumbing codes and proper installation practices prescribe the size, type, pitch and layout of the drainage pipes to ensure that waste will run downhill through the pipes to the sewer or septic systems without clogging the pipes. With new construction, there is the opportunity to match the sanitaryware with a pipe system that is designed to work with the sanitaryware to provide a drainage system designed to avoid blockages. However, when sanitaryware are connected to a drainage system that is not so matched, such as during bathroom remodeling when new sanitaryware are connected to older pipes, there is an increased risk of blockages. Cleaning out a clogged drainage system can be a daunting and expensive undertaking.
[0004] Regarding the sanitaryware, a toilet is generally either of the type that relies on a water storage tank to force Water into the bowl causing it to “flush” or of the type that does not. In most cases, urinals don't rely on water storage tanks as a water delivery system.
[0005] Tank toilets, which are common in residential settings, are gravity-powered. With siphonic toilets, for example, when the toilet is flushed, the water in the tank rushes down with enough force to activate a siphon, which is a tube at the bottom of the bowl fixture. The siphon pulls the water and waste out of the bowl and into the drainage line. A flush valve controls the flow of water from the tank into the bowl.
[0006] Tankless toilets, which are common in commercial and/or public settings, receive water directly from a supply line at a high enough pressure that a single flush can carry waste through the drainage system. Tankless toilets use approximately the same amount of water as a tank-type toilet. For the most part, these toilets are powered using only the force of water entering from the supply line (in buildings where water pressure is an issue, the flush can be assisted by pumps). Tankless toilets generally need about 25 psi or more of water pressure to function properly. Most urinals require less water pressure (and much less water to complete a flush) because they flush liquid not solid waste.
[0007] Most tankless toilets and urinals operate using a flush valve that is metered with either a piston or a diaphragm. The valve is designed to shut automatically after completing a flush cycle.
[0008] With the advent of low flush volume toilets and urinals, the proper flushing and purging of the drainage system has become a serious concern. For example, a decade ago, it was not uncommon to have a toilet use in excess of 3 gallons of water per flush. Given present day water conservation efforts, various plumbing codes currently mandate that toilets use a maximum of 1.1 or 1.28 or 1.6 gallons per flush (typically' less for urinals). This presents the problem of providing enough water per flush for sufficient drainage line carry-out of solid waste and to prevent undesirable buildup of minerals, etc. on the inside surfaces of the fixtures and drainage pipes. The problem is compounded by government incentives, such as Leadership in Energy and Environmental Design (“LEED”), a voluntary, consensus-based, market-driven program that provides third-party verification of green buildings, and similar programs that incentivize building owners to reduce water consumption, without regard to the consequential, negative effects on fixtures and drainage, systems.
[0009] There is therefore a need for a way to provide for water conservation while minimizing the negative effects of the reduced water flow in low flow sanitaryware fixtures and drainage pipe systems.
SUMMARY OF THE INVENTION
[0010] Generally speaking, it is an object of the present invention to provide a control device, method and system for effecting a selectable, periodic heavier flush volume of water after a preselected number of normal low volume flushes and/or after a preselected period of inactivity of the toilet or urinal to provide sufficient drainage line carry-out of waste and to prevent undesirable buildup of minerals, etc. on the inside surfaces of the fixtures and drainage pipes.
[0011] Still other objects and advantages of the present invention will in part be obvious and will in part be apparent from the specification.
[0012] The present invention accordingly comprises the features of construction, combination of elements, arrangement of parts, and the various steps and the relation of one or more of such steps with respect to each of the others, all as exemplified in the constructions herein set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF TUE DRAWINGS
[0013] For a fuller understanding of the inventive embodiments, reference is had to the following description taken in connection with the accompanying drawings in which:
[0014] FIG. 1 is an exploded view of an exemplary commercially available flush valve for a commercial tankless toilet;
[0015] FIGS. 2A and 2B depict an exemplary commercially available flush valve for a urinal (front and side views); and
[0016] FIG. 3 depicts an exemplary layout of a plumbing system including sanitaryware fixtures strategically equipped with periodic heavy flush valve control devices in accordance with embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The present invention provides embodiments of a periodic heavy flush valve control device (hereinafter, “PHFD”), method and system that cause the flush valve to periodically effect a heavy flush sufficient to help purge (in whole or in part) the fixture (especially, the trap) and the drainage line to which it is connected of undesirable blockages caused by waste and mineral buildup. The flush volume (which can be based on the duration of the flush) can be selected/adjusted to ensure that it is within the capability of the sanitaryware to drain that amount of water without overflow. This heavy flush exceeds the prescribed flush volume for a normal flush; i.e., it can be greater—even much greater—than the current normal 1.1, 1.28 or 1.6 gallons for toilets and 0.5 or 1 gallon for urinals. By way of example, and without limitation, the heavy flush volume can range from about 10% greater than a normal flush to as much as 3, 4 or 5 gallons or more.
[0018] The PHFD can be a separate device from the flush valve. As such, it can be attached directly to the drainage line system to permit purging.
[0019] According to one embodiment of the present invention, the PHFD functionality can be incorporated into the sanitaryware flush valve itself as a suitably programmed expansion of the valve functionality. This presumes use of an electronic flush valve, such as for example an American Standard SELECTRONIC™ flush valve.
[0020] FIG. 1 is an exploded view of an American Standard SELECTRONIC™ proximity toilet flush valve 10 —an exemplary commercially available flush valve for a commercial tankless toilet (1.1, 1.28 and 1.6 gallons-per-flush or “GPF”). The flush valve 10 , which can be battery' powered, includes a cover assembly 12 , which connects (e.g., via a bonnet nut 14 ) to a main body 16 . The cover assembly 12 houses a sensor assembly 18 ; the main body 16 houses a solenoid valve and piston subassembly including a solenoid valve assembly 20 and a piston assembly 22 . A manual valve 24 connects to the main body 16 , as does an adjustable tailpiece 26 . The adjustable tailpiece 26 connects the main body 16 to an inlet, pipe assembly 28 via a supply stop 30 (with cap 32 ). A vacuum breaker assembly 34 also connects to the main body 16 ; an escutcheon assembly 36 , in turn, connects to the vacuum breaker assembly 34 .
[0021] FIGS. 2A and 2B show front and side views, respectively, of an American Standard SELECTRONIC™ urinal flush valve 40 —an exemplary commercially available, battery powered, sensor operated flush valve for a urinal (1 GPF), Flush valve 40 is shown mounted both atop a urinal 42 and to the plumbing behind a bathroom wall 44 .
[0022] Advantageously, flush valves of the type under consideration can receive the programmed PHFD functionality and any adjustments thereto using a remote programmer/control device. Indeed, the sanitaryware flush valve sensor assembly (see, e.g., sensor assembly 18 shown in FIG. 1 ) can include a multi-function sensor, which can be suitably programmed with the PHFD functionality. Such a sensor can be provided for use on a variety of types of sanitaryware fixture—with the programming adapting it to its particular function for the particular fixture on which it is used.
[0023] By incorporating the PHFD functionality into toilet or urinal flush valves, the flush valves can provide normal, efficient flush volumes when not providing heavy periodic flushes. Advantageously, by virtue of the PHFD functionality, normal flush volumes can even be further reduced (further aiding water conservation efforts), as the periodic heavy flushes can be programmed or adjusted (in intensity and/or periodicity) to compensate for the lower flush volumes while ensuring sufficient fixture (especially, trap) and drainage line clearance.
[0024] PHFDs can be strategically located (and enabled or disabled as appropriate) at different points of the drainage system where low usage or insufficiently pitched pipes may benefit from the periodic higher flush volume of water to help purge the drainage lines. Periodic delivery of larger flush volumes to the drainage system based on the location of the flush valves enables a coordinated and networked system approach to balancing water conservation efforts and drainage line clearance requirements.
[0025] FIG. 3 depicts an exemplary layout of a building plumbing system illustrating how/where inventive PHFDs may be deployed to address drainage line carry-out with high efficiency toilets (“HET”) and/or ultra-high efficiency toilets (“UHETs”). At upper level A, seven frequently used toilets 52 A equipped with inventive PHFD functional flush valves 54 A share a common branch drainage line 56 A, which feeds into a main drainage line 58 . At mid-level B, four toilets 52 B equipped with inventive PHFD functional flush valves 54 B share a common branch drainage line 56 B feeding into the main line 58 , with one seldom-used fixture occupying the distal end of the branch line remote from the other three more frequently used fixtures on the common line. At lower level C, three toilets 52 C equipped with inventive PHFD functional flush valves 54 C share a common branch drainage line 56 C feeding into the main line 58 . The toilets 52 C are disposed at spaced-apart points on the line; and an undesirable sag 60 in the drainage line 56 C exists between two of the fixtures.
[0026] According to one embodiment of the present invention, the flush valve can be controlled to execute a heavy, drainage-purging flush after a preselected number (or count) of normal flushes. Referring to FIG. 3 , the middle of the seven frequently used toilets 52 A is a good candidate for such drainage line purge flushing based on the number of uses.
[0027] An alternative embodiment utilizes a selectable period of inactivity to execute the heavy, drain-purging flush. ideally, this functionality can be provided on the drainage line at the end of one of the farthest locations (main or branch lines) from the building drain exit to help purge the entire drainage line (enabling a drainage line purge cycle). The selectable period of inactivity for execution of the flush can be anywhere from hours to days to avoid wasting water while helping to prevent blockages. The amount of water flushed for this periodic flush is also adjustable to avoid wasting water and to ensure that the fixture or pipe it is attached to can handle the volume of water without issue. Referring to FIG. 3 , the toilets 52 B and 52 C that occupy the respective ends of the branch lines 56 B and 56 C farthest from the main line 58 are good candidates for such drainage line purge flushing based on period of non-use.
[0028] Another embodiment combines both the selectable period of inactivity and the selectable count of normal flushes with independent resulting selectable flush volumes. Referring to FIG. 3 , the middle of the three toilets 52 C, given its upstream proximity to the drainage line sag 60 , is a good candidate for drainage line purge flushing at a selected high flush volume based on one or both of the number of uses and period of non-use.
[0029] Additionally, the periodic heavy flushes can be programmed to execute at preselected times periods during the day or night. This can take into account the variations in available water pressure based on building water usage.
[0030] Accordingly, the inventive embodiments capitalize on the use of high efficiency, low water volume flush valve systems without a drastic impact on LEED or similar conservation credit calculations. Effecting periodic heavy flushes after a selectable period of flush valve inactivity or a selectable number of normal flushes, combined with a selectable flush volume, is salutary in that it permits maximum water savings of high efficiency toilets, urinals, and related flush valves while providing enough frequency and flush volume to minimize drainage line build-up or blockages.
[0031] Table 1 below illustrates water conservation benefits of using inventive PHFDs with ultra-high efficiency sanitaryware fixtures compared to less efficient fixtures such as, for example, standard 1.6 GPF flushing systems.
[0000]
TABLE 1
%
#
Flush
Savings
Toi-
Vol-
Flushes/
Total
Savings
vs. 1.6
lets
ume
Day
Gallons
(gal.)
GPF
1.6 GPF Standard
14
1.60
10
224.0
0
0%
Toilets
1.28 GPF HET
14
1.28
10
179.2
44.8
20%
Toilets
1.10 GPF UHET
14
1.10
10
154.0
Toilet Systems.
Additional flush
3
1.60
3
14.4
from time out ‘non-
use’
168.4
55.6
25%
1.10 GPF UHET
14
1.10
8
123.2
Toilet Systems.
1 heavy flush every
14
1.60
2
44.8
5 flushes
168.0
56.0
25%
1.10 GPF UHET
11
1.1
10
121.0
Toilet Systems.
3 heavy flushes/day
3
1.1
7
23.1
for 3 flush valves
3
1.6
3
14.4
based on count
usage
158.5
65.5
29%
[0032] Moreover, the inventive embodiments provide building owners with the salutary capability to adjust the drainage profile of their buildings' drainage systems as a whole as needed via selective control of the sanitaryware flush valves. This is particularly advantageous for buildings where the pipes are sealed behind walls, above ceilings and under floors, and, from a practical standpoint, it is not an option to change them. Referring to FIG. 3 , a good example of this is the capability to enlist and fully leverage the middle of the three toilets 52 C to effect drainage line purge flushes to address the drainage issues presented by the drainage line sag 60 .
[0033] It should be appreciated that the inventive embodiments constitute a significant contribution to the art. The closest-appearing art includes flush valves that can merely provide an automatic 24 hour sanitary flush, which is typically a full flush (based on rating of flush valve installed) or a short flush after an inactivity period of 24 hours, While this provides a cleansing flush for the toilets or urinals and/or provides water to maintain the drain trap seal preventing sewer gases from coming up through the fixtures), it does nothing to ensure that flush volumes are adequate to clear and keep the drainage lines free of blockages, let alone take into account the location of the flush valve in the drainage system for the purpose of purging it.
[0034] Embodiments of the present invention can be implemented in the form of control logic in software or hardware or a combination of both. For example, particular embodiments can be implemented by using application specific integrated circuits or programmed logic circuits, in general, the functions of particular embodiments can be achieved by any suitable means as is known in the art. Communication or transfer of data or instructions may be wired, wireless, or by any other suitable means. Also, elements of the inventive embodiments can be enabled or disabled as is useful in accordance with a particular application.
[0035] Furthermore, it should be understood that the aspects, features and advantages made apparent from the foregoing are efficiently attained and, since certain changes may be made in the disclosed inventive embodiments without departing from the spirit and scope of the invention, it is intended that all matter contained herein shall be interpreted as illustrative and not in a limiting sense.
[0036] 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 that, as a matter of language, might be said to fall therebetween. | The smaller volumes of water currently required to flush toilets and urinals may be insufficient to clear the fixtures and the drainage lines to which they are connected of waste and other undesirable materials, which can build up over a period of flushes or non-use. A flush valve control device programmed or otherwise configured to provide a selectable, periodic heavier flush volume of water after a predetermined number of low volume flushes and/or after a predetermined period of inactivity of the toilet or urinal can provide for sufficient drainage line carry-out of waste and prevent undesirable buildup of minerals, etc. on the inside surfaces of the fixtures and drainage pipes. | 8 |
BACKGROUND OF THE INVENTION
Field of the Invention
Embodiments of the present invention generally relate to a method and apparatus for temporarily sealing a bore of a tool. More particularly, the invention relates to a ball seat and a method and apparatus for remotely releasing the ball.
Description of the Related Art
In the completion and operation of a hydrocarbon well, it is often necessary to remotely actuate a downhole tool in order to move the tool from a first to a second state. In one example, a packer is run into the well on a string of tubulars and then actuated, thereby causing sealing members to extend radially outwards into sealing contact with walls of the wellbore. One way of remotely actuating the tool is through a temporary increase in fluid pressure adequate to shift a piston formed on the tool that in turn causes the sealing members to move. In order to increase pressure in the area of the tool, the wellbore is typically blocked at a location below the tool. In one instance, the wellbore is blocked with a ball and ball seat. In one example, a ball is dropped from the surface of the well into the ball seat. With the bore blocked, pressure is increased to a point that sets the tool. Thereafter, pressure is increased to a higher level in order to “blow out ” the ball seat, permitting the ball to fall through the seat and the bore to be re-opened. While the forgoing arrangement is operable, it necessarily requires high pressures, especially to blow out the ball seat. High pressure can damage hydrocarbon-bearing formations through shock loading due to pressure surge or water hammer effect.
There is a need therefore, for a ball and seat arrangement wherein the ball can be released from the seat without the use of a fluid pressure differential across the seat.
SUMMARY OF THE INVENTION
The present invention generally relates to a downhole device for shifting a component from a first state to a second state. In one embodiment, the device includes a body having the component in a bore thereof and an annular space formed within an inner and outer wall of the body. The annular space includes a first fluid chamber in fluid communication with the bore at a first location and with a pressure transducer at a second location, the transducer constructed and arranged to measure pressure of the fluid and provide a signal to circuitry controlling a valve upon reception of a predetermined pressure pulse sequence. When the pulse sequence is delivered, the valve opens, placing a source of pressurized fluid in communication with an actuator that shifts the valve.
BRIEF DESCRIPTION OF THE DRAWINGS
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.
FIG. 1 is a cross section view of a tool according to one embodiment of the invention.
FIG. 2 is a cross section view of the tool of FIG. 1 shown in a different rotational position.
FIG. 3 is a cross section view showing two portions of the tool in greater detail.
FIG. 4 is a cross section view showing a valve assembly with a valve shown in a closed position.
FIG. 5 is a cross section view showing the valve in an open position.
FIGS. 6 and 7 are section views of the valve in a different rotational position, shown in the open and closed positions, respectively.
FIG. 8 is a cross section view showing a lower portion of the tool including a ball seat with a ball held therein.
FIGS. 9 A-D are perspective views of the ball seat.
FIG. 10 is a cross section view shown the lower portion of the tool wherein the ball seat has been shifted to an enlarged diameter position.
DETAILED DESCRIPTION
The present invention relates to a downhole tool for temporarily blocking and un-blocking a flow path through a wellbore. More particularly, the invention relates to a ball and ball seat wherein the ball can be released from the seat without the use of a pressure differential across the seat.
FIG. 1 is a cross section view of a tool 100 according to one embodiment of the invention. The tool is constructed and arranged to be installed in a tubular string, typically production string (not shown) and is provided with threaded connections at an upper and lower ends. As shown, the tool includes a central bore 105 , the bore including a ball seat 200 , shown in a reduced diameter position with a ball 201 therein. In the position of FIG. 1 , the ball and ball seat are configured to block the bore 105 of the tool 100 and permit pressure to be developed in the wellbore at any location above the tool. Another tool needing pressure actuation would typically be disposed in the tubular string at a location above the tool 100 . The tool is constructed with an annular space formed between an inner 101 and outer 102 walls and in one embodiment of the invention; components are housed in the annular space. The various components are shown in greater detail in other Figures but the primary portions include a wellbore fluid chamber 110 , an annular piston 115 , a hydraulic fluid chamber 120 , electronic circuitry 125 and batteries 130 . Additionally, a number of interconnected fluid paths are formed in the annular space as well as a valve assembly 300 with a valve that is remotely openable to expose pressurized fluid in the fluid paths to an annular piston 150 that shifts the ball seat 200 to its larger diameter position in order to release the ball 201 and un-block the bore 105 .
FIG. 2 is a cross section view of the tool of FIG. 1 shown in a different rotational position and illustrates a first fluid path 250 (shown on the left side of the annular space) in greater detail. FIG. 3 is a cross section view showing two portions of the tool 100 in greater detail. In particular, the upper portion of the Figure illustrates an aperture 122 leading from the bore 105 of the tool to the annular wellbore fluid chamber 110 . The aperture 122 permits fluid pressure communication between the bore and the first fluid path 250 disposed in the annular area of the tool. As will be shown, the pressure of the fluid in the bore, and with it the pressure in the annular chambers 110 , 120 can be increased or decreased and delivered in pulses. A predetermined delivery of such pulses can be used to open the valve and ultimately shift the ball seat 200 from the smaller diameter position of FIG. 1 to a larger diameter position. Wellbore fluid chamber 110 is separated from hydraulic fluid chamber 120 by an annular piston 115 in order to prevent contamination of the hydraulic fluid while allowing it to be effected by pressure and pulses from the bore of the tool. The first fluid path 250 extends from the hydraulic fluid chamber 120 to a tubing pressure transducer 155 that is placed in the fluid path 250 where it receives and measures pressures and pulses in the bore of the tool as well as timing associated with those pressures and pulses and then generates an electrical signal based upon those values to circuitry 125 disposed in an adjacent area of the annular space ( FIG. 1 ). The first fluid path 250 is connected to a second fluid path 252 extending from one side of the annular space to the other. Located just above the tubing pressure transducer 155 on the left side of the Figure is a port 254 that leads into the second fluid path 252 around the annular body terminating at another port 255 visible on the right side of the Figure. Port 255 , in turn is connected to a third fluid path 256 that leads to the valve assembly 300 not visible in FIG. 3 but visible in FIG. 4 .
FIG. 4 is a cross section view showing the valve assembly 300 with a valve 302 shown in a closed position. As shown, the third fluid path 256 leads to the valve. In the embodiment shown, the valve assembly 300 includes a Kevlar fuse 350 which is designed to operate based upon an electronic signal from the on-board circuitry 125 in the tool 100 . The valve 302 includes a plunger 305 which in the closed position, blocks a fluid path through the valve 302 that otherwise connects the third fluid path entering the valve with a fourth fluid path 258 leading from valve. The plunger 305 is biased towards an open position due to a spring 306 but is initially held in a closed position, against the force of the compressed spring by retaining members 310 that are equipped with electrodes (partially shown) 312 causing them to fail in the event of a predetermined electrical signal from the circuitry 125 . One example of a Kevlar fuse-type device is shown and described in U.S. Pat. No. 5,558,153 and that patent is incorporated by reference in its entirety herein.
FIG. 5 is a cross section view showing the valve 302 in an open position. As shown, the retaining members 310 have been caused to fail and the plunger 305 has been moved from a first closed position ( FIG. 4 ), in which port 257 is blocked by the plunger 305 , to an second, open position ( FIG. 5 ) wherein fluid traveling in port 257 is free to enter and pass through the valve due to the extended spring 306 which was initially held in a compressed position. FIGS. 6 and 7 are section views of the valve assembly 300 from a different rotational position, shown in the open and closed positions, respectively. Visible in each is the valve 302 with its plunger 305 biased by the spring 306 . In FIG. 6 the port 257 (not shown) leading into the valve is blocked by a plunger member 307 . In FIG. 7 however, port 257 is visible and the fluid therein is in communication with the fourth fluid path 258 leading out of the valve.
FIG. 8 is a cross section view showing a lower portion of the tool 100 including ball seat 200 with ball 201 held therein. The ball seat is constructed of a plurality of castellations 202 , equally spaced around a perimeter of a sealing ring 205 and more completely illustrated in FIGS. 9 A-D, which include various perspective views of the ball seat 200 . Each castellation 202 has an angled inner surface 203 and is mounted at a lower end to a sealing ring 205 . The ring 205 includes at least one O-ring (visible in FIGS. 8, 10 ) for sealing against an upwardly facing shoulder 207 formed in the body of the tool and constructed and arranged to retain and seal the ball seat 200 in the bore 105 of the tool 100 . The purpose of the angled inner surface 203 of each castellation 202 is to mate with and move upwards relative to a conical surface 210 formed on an outer diameter of a sleeve 211 installed in the bore 105 of the tool above the ball seat 200 . Visible in FIG. 8 is an annular shifting piston 150 with a piston surface 152 formed on a lower end thereof and in communication with the lower end of fourth fluid path 258 extending from the valve 302 (when the valve is open). A space 153 above the piston 150 is filled with air at atmospheric pressure permitting the gap to be reduced in volume as the piston moves.
FIG. 10 is a cross section view showing the lower portion of the tool 100 wherein the ball seat 200 has been shifted to an enlarged diameter position. As shown, the annular shifting piston 150 has moved from a first lower to a second higher position relative to the ball seat due to fluid pressure acting on the piston surface 152 of the piston 150 . Consequently, the space 153 has been reduced in volume. In operation, an upwardly facing shoulder 154 of the annular piston 150 that is in contact with a lower surface 212 of the castellations 202 has forced the ball seat 200 with its castellations 202 upwards along the conical surface 210 , thereby enlarging the inner diameter of the sealing ring 205 to a size exceeding the outer diameter of the ball 201 . In this manner, the ball is released and fluid communication is reestablished between the portions of the bore above and below the ball seat 200 .
In one embodiment, the invention is practiced in the following manner: A tool 100 including the ball seat 200 is run into a wellbore in a string of tubulars to a predetermined depth. The ball seat is in its smaller diameter position as shown in FIG. 1 , however, the bore through the tool is open because there is no ball in the seat during run in. At some later time, an operator decides to set a pressure-actuated tool, like a packer disposed in the string above the tool 100 . A ball is dropped from the surface and lands in the seat as shown in FIG. 1 . With the bore of the tool blocked, pressure in the tubular string is increased to a predetermined threshold, typically by pumping from the surface, until the pressure-actuated tool is set. Thereafter, there is a need to remove the ball from the seat and reopen the bore through the tool.
In one embodiment, the ball seat 200 is shifted from its smaller to larger diameter state based upon predetermined parameters consisting of signals to circuitry 125 housed in the tool. Those signals begin as pressure pulses delivered to the tubing pressure transducer 155 from the bore of the tool via aperture 122 ( FIG. 3 ). A complete “pulse” in one instance is a specified pressure applied via the tubing to the tubing pressure transducer followed by a “bleeding off” of that pressure to zero. In one example, the circuitry is programmed to operate the Kevlar fuse of the valve assembly 302 in the event that it receives data from the transducer 155 indicating three separate and distinct pulses have been received. In another example, the data includes not only pulses but pulses separated by a predetermined time delay in seconds or minutes. Additionally, the circuitry can include programming that delays the operation of the fuse for a predetermined period of time after the data has been received. Numerous variations are available limited only by the ability to provide pulses from the bore of the tool to the transducer 155 . In one embodiment, an annulus pressure transducer 156 ( FIG. 1 ) is provided. The annulus pressure transducer is in fluid communication with the annulus between the tool 100 and the wellbore walls. By calculating the difference between tubing and annulus pressure, an effective pressure can be determined and that effective pressure data provided to the circuitry for operation of the valve assembly 302 with its Kevlar fuse.
Once conditions for operation of the Kevlar fuse have been met, the electrodes operate to break the retaining members retaining the valve 302 in a closed position and the valve moves from the closed position of FIG. 4 to the open position of FIG. 5 . As described in conjunction with FIG. 5 , the open valve permits fluid to flow into the fourth fluid path 258 to the annular shifting piston 150 , thereby moving the ball seat from the position of FIG. 8 to the position of FIG. 10 . With the seat 200 in its larger diameter position, the ball 201 is released, the bore 105 unblocked and wellbore operations can be resumed without having subjected the wellbore and surrounding formations to a pressure surge.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | A downhole device shifts a component from a first state to a second state. The device includes a body having the component in a bore thereof and an annular space formed within an inner and outer wall of the body. The annular space includes a first fluid chamber in fluid communication with the bore at a first location and with a pressure transducer at a second location, the transducer constructed and arranged to measure pressure of the fluid and provide a signal to circuitry controlling a valve upon reception of a predetermined fluid pressure pulse sequence. When the pulse sequence is delivered, the valve opens, placing a source of pressurized fluid in communication with an actuator that shifts the valve. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a divisional application of the U.S. application Ser. No. 10/507,231, filed on Sep. 9, 2004, entitled “STRETCH FABRIC WITH IMPROVED CHEMICAL RESISTANCE AND DURABILITY,” the teachings of which are incorporated by reference herein, as if reproduced in full hereinbelow, which is a 371 National Stage of International Application No. PCT/US2003/007592, filed on Mar. 11, 2003, entitled “STRETCH FABRIC WITH IMPROVED CHEMICAL RESISTANCE AND DURABILITY,” the teachings of which are incorporated by reference herein, as if reproduced in full hereinbelow, and which claims priority from the U.S. Provisional Application No. 60/363,127, filed on Mar. 11, 2002, entitled “STRETCH FABRIC WITH IMPROVED CHEMICAL RESISTANCE AND DURABILITY,” the teachings of which are incorporated by reference herein, as if reproduced in full hereinbelow. U.S. Provisional Application No. 60/363,127 is a continuation-in-part of U.S. Ser. No. 09/627,534 filed on Jul. 28, 2000.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to stretch fabrics. In one aspect, the invention relates to stretch fabrics comprising synthetic and natural fibers while in another aspect, the invention relates to such fabrics comprising crosslinked, heat-resistant elastic fibers capable of withstanding dyeing and heat-setting processes. The crosslinked, heat-resistant elastic fibers are 25 useful in various durable or repeated-use fabric applications such as, but not limited to, clothing, undergarments, sports apparel and upholstery. The crosslinked, heat-resistant elastic fibers can be conveniently formed into fabrics using well-known techniques such as, for example, by using co-knitting techniques with cotton, nylon, and/or polyester fibers.
[0003] A material is typically characterized as elastic if it has a high percent elastic recovery (that is, a low percent permanent set) after application of a biasing force. Ideally, elastic materials are characterized by a combination of three important properties, i.e., (i) a low percent permanent set, (ii) a low stress or load at strain, and (iii) a low percent stress or load relaxation. In other words, there should be (i) a low stress or load requirement to stretch the material, (ii) no or low relaxing of the stress or unloading once the material is stretched, and (iii) complete or high recovery to original dimensions after the stretching, biasing or straining is discontinued.
[0004] To be used in the durable fabrics, the fibers making up the fabric have to be, inter alia, stable during dyeing and heat setting processes. For an elastic polyolefin fiber to be stable under dyeing and heat-setting conditions, it must be crosslinked. These fibers can be crosslinked by one or more of a number of different methods, e.g., e-beam or UV irradiation, silane or azide treatment, peroxide, etc., some methods better than others for fibers of a particular composition. For example, polyolefin fibers that are irradiated under an inert atmosphere (as opposed to irradiated under air) tend to be highly stable during dyeing processes (that is, the fibers do not melt or fuse together). The addition of a mixture of hindered phenol and hindered amine stabilizers further stabilized such fibers at heat setting conditions (200-2100 C).
[0005] Lycra®, a segmented polyurethane elastic material manufactured by E. I. du Pont de Nemours Company, is currently used in various durable stretch fabrics. Lycra, however, is not stable at the typical high heat-setting temperatures (200-210° C.) used for polyethylene terephthalate (PET) fiber. Moreover, and similar to ordinary uncrosslinked polyolefin-based elastic materials, Lycra fabrics tend to lose their integrity, shape and elastic properties when subjected to elevated service temperatures such as those encountered in washing, drying and ironing. As such, Lycra can not be easily used in co-knitting applications with high temperature fibers such as polyester fibers.
SUMMARY OF THE INVENTION
[0006] According to this invention, a stone-washed fabricated article comprises a fabric that comprises a heat-resistant, crosslinked olefin elastic fiber and an inelastic fiber. In one embodiment, the fabric is a durable stretch fabric made and processed from one or more crosslinked, heat-resistant olefin elastic fibers. The fabrics can be made by any process, e.g., weaving, knitting, etc., and from any combination of crosslinked, heat-resistant olefin elastic and inelastic (“hard”) fibers. These fabrics exhibit excellent chemical, e.g., chlorine, resistance and durability, e.g., they retain their shape and feel (“hand”) over repeated exposure to service conditions, e.g., washing, drying, etc. For example, in one embodiment the fabric has a change in elasticity not in excess of about 10% and/or retains at least about 50% of its growth after exposure to a 5% by weight permanganate solution for a period of at least 90 minutes at a temperature of at least 140 F. In another embodiment, the fabric retains at least about 10% of its elasticity and/or at least about 50% of its growth after exposure to a 10% by weight hypochlorite solution for a period of at least 90 minutes at a temperature of at least 140 F.
[0007] The crosslinked, heat-resistant olefin elastic fibers include ethylene polymers, propylene polymers and fully hydrogenated styrene block copolymers (also known as catalytically modified polymers). The ethylene polymers include the homogeneously branched and the substantially linear homogeneously branched ethylene polymers as well as ethylene-styrene interpolymers. The other fibers of the fabric can vary widely, and they include virtually all know natural and synthetic fibers, particularly inelastic fibers. Typical of these other fibers are cotton, wool, silk, nylon, polyester, and the like. Usually the crosslinked, heat-resistant olefin elastic fibers comprise a minority of the fabric on a weight basis.
[0008] The fabrics of this invention include (i) a stone-washed elastic cotton fabric, (ii) a dye-stripped elastic nylon fabric, (iii) a brilliant-colored, dyed elastic polyester (e.g., PET) fabric, (iv) a dry-cleaned elastic fabric (e.g., a fabric that has been exposed to perchloroethylene), and (v) a chlorine- or bromine-exposed elastic fabric comprising one or more of polyester, nylon and cotton. All of these fabrics have been exposed to harsh and stringent processes that utilize chemicals and conditions that would degrade most conventional stretch fabrics because these chemicals and conditions would degrade the stretch fiber component of these fabrics. The fabrics of this invention, however, comprise a stretch fiber that is particularly resistant to such degradation and as such, the fabric containing these fibers exhibits surprising durability and chemical resistance.
BRIEF DESCRIPTION OF THE FIGURES
[0009] The FIG. 1 is a photograph of four heavy weight, denim fabric samples comprising fiber made from AFFINITY ethylene/1-octene copolymer. Each sample was subjected to a different stone wash protocol, i.e., the first (or top) sample to a vintage wash, the second to an antique wash, the third to a destructive wash, and the fourth (or bottom) sample to a bleach-out wash. The stretch properties of each sample after the washing protocol were essentially the same as the stretch properties before the washing protocol. The dark blue patch on top of the first or top sample is the color of each sample before it was stone washed.
[0010] FIG. 2 is a Scanning Electron Microscopy (SEM) image of a Speedo swimsuit after a five-month wear test. The suit is of a tricot warp knit structure made with a chlorine-resistant Lycra™ fiber.
[0011] FIG. 3 is an SEM image of the swimsuit of FIG. 2 showing the loop structure under enhanced magnification.
[0012] FIG. 4 is a SEM image of a Speedo swimsuit after a four-month wear test. The suit is of a weft knit single jersey structure made with a crosslinked AFFINITY ethylene/1-octene copolymer fiber.
[0013] FIG. 5 is an SEM image of the swimsuit of FIG. 4 showing the loop structure under enhanced magnification.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] “Fiber” means a material in which the length to diameter ratio is greater than about 10. Fiber is typically classified according to its diameter. Filament fiber is generally defined as having an individual fiber diameter greater than about 15 denier, usually greater than about 30 denier. Fine denier fiber generally refers to a fiber having a diameter less than about 15 denier. Microdenier fiber is generally defined as fiber having a diameter less than about 100 microns denier.
[0015] “Filament fiber” or “monofilament fiber” means a single, continuous strand of material of indefinite (i.e., not predetermined) length, as opposed to a “staple fiber” which is a discontinuous strand of material of definite length (i.e., a strand which has been cut or otherwise divided into segments of a predetermined length).
[0016] The term “heat resistant” as used herein refers to the ability of an elastic polymer or elastic polymer composition in the form of fiber to pass the high temperature heat setting and dyeing tests described herein.
[0017] The term “elastic article” is used in reference to shaped items, while the term “elastic material” is a general reference to polymer, polymer blends, polymer compositions, articles, parts or items. “Elastic” means that a fiber will recover at least about 50 percent of its stretched length after the first pull and after the fourth to 100% strain (doubled the length). Elasticity can also be described by the “permanent set” of the fiber. Permanent set is the converse of elasticity. A fiber is stretched to a certain point and subsequently released to the original position before stretch, and then stretched again. The point at which the fiber begins to pull a load is designated as the percent permanent set. “Elastic materials” are also referred to in the art as “elastomers” and “elastomeric”. Elastic material (sometimes referred to as an elastic article) includes the polyolefin polymer itself as well as, but not limited to, the polyolefin polymer in the form of a fiber, film, strip, tape, ribbon, sheet, coating, molding and the like. The preferred elastic material is fiber. The elastic material can be either cured or uncured, radiated or unradiated, and/or crosslinked or uncrosslinked. For heat reversibility, the elastic fiber must be substantially crosslinked or cured.
[0018] “Nonelastic material” means a material, e.g., a fiber, that is not elastic as defined above.
[0019] “Meltblown fibers” are fibers formed by extruding a molten thermoplastic polymer composition through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity gas streams (e.g. air) which function to attenuate the threads or filaments to reduced diameters. The filaments or threads are carried by the high velocity gas streams and deposited on a collecting surface to form a web of randomly dispersed fibers with average diameters generally smaller than 10 microns.
[0020] The term “spunbond” is used herein in the conventional sense to refer to fibers formed by extruding the molten elastic polymer or elastic polymer composition as filaments through a plurality of fine, usually circular, die capillaries of a spinneret with the diameter of the extruded filaments then being rapidly reduced and thereafter depositing the filaments onto a collecting surface to form a web of randomly dispersed spunbond fibers with average diameters generally between 7 and 30 microns.
[0021] The term “nonwoven” as used herein and in the conventional sense means a web or fabric having a structure of individual fibers or threads which are randomly interlaid, but not in an identifiable manner as is the case for a knitted fabric. The elastic fiber of the present invention can be employed to prepare inventive nonwoven elastic fabrics as well as composite structures comprising the elastic nonwoven fabric in combination with nonelastic materials.
[0022] The term “conjugated” refers to fibers which have been formed from at least two polymers extruded from separate extruders but meltblown or spun together to form one fiber. Conjugated fibers are sometimes referred to in the art as multicomponent or bicomponent fibers. The polymers are usually different from each other although conjugated fibers may be monocomponent fibers. The polymers are arranged in substantially constantly positioned distinct zones across the cross-section of the conjugated fibers and extend continuously along the length of the conjugated fibers. The configuration of conjugated fibers can be, for example, a sheath/core arrangement (wherein one polymer is surrounded by another), a side by side arrangement, a pie arrangement or an “islands-in-the sea” arrangement. Conjugated fibers are described in U.S. Pat. No. 5,108,820, 5,336,552 and 5,382,400. The elastic fiber of the present invention can be in a conjugated configuration, for example, as a core or sheath, or both.
[0023] The term “thermal bonding” is used herein refers to the heating of fibers to effect the melting (or softening) and fusing of fibers such that a nonwoven fabric is produced. Thermal bonding includes calendar bonding and through-air bonding as well as methods known in the art. The expression “thermal bondable at a reduced hot melt adhesive amount” refers to comparative peel test results using Ato Findley Adhesive HX9275 (supplied by Ato Findley Nederlands B. V., Roosendaal, The Netherlands) or H. B. Fuller Adhesive D875BD1 (supplied by H. B. Fuller GmbH, IOneburg, Germany) and test procedures and methods described in WO 00/00229, wherein the same peel strength as the adhesive without deploying thermal bonding can be obtained even though the quantity of adhesive is at least 15 percent less where thermal bonding is deployed.
[0024] The term “polymer”, as used herein, refers to a polymeric compound prepared by polymerizing one or more monomers. As used herein, generic term “polymer” embraces the terms “homopolymer,” “copolymer,” “terpolymer” as well as “interpolymer.” A polymer is usually made in one reactor or polymerization vessel but can as well as be made using multiple reactors or polymerization vessels, although the latter is usually referred to as a polymer composition.
[0025] The term “polymer composition” as used herein refers to a mixture of a polymer and at least one ingredient added to or mixed with the polymer after the polymer is formed. Thus, the term “polymer composition” includes poly-blends (that is, admixtures of two or more polymers wherein each polymers is made in separate reactors or polymerization whether or not the reactors or vessels are part of the same polymerization system or not).
[0026] The term “interpolymer”, as used herein refers to polymers prepared by the polymerization of at least two different types of monomers. As used herein the generic term “interpolymer” includes the term “copolymers” (which is usually employed to refer to polymers prepared from two different monomers) as well as the term “terpolymers” (which is usually employed to refer to polymers prepared from three different types of monomers).
[0027] “Radiated” or “irradiated” means that the elastic polymer or polymer composition or the shaped article comprised of the elastic polymer or elastic composition was subjected to at least 3 megarads (or the equivalent of 3 megarads) of radiation dosage whether or not it resulted in a measured decrease in percent xylene extractables (i.e., an increase in insoluble gel). Preferably, substantial crosslinking results from the irradiation. “Radiated” or “irradiated” may also refer to the use of UV-radiation at an appropriate dose level along with optional photoinitiators and photocrosslinkers to induce crosslinking.
[0028] The terms “crosslinked” and “substantially crosslinked” as used herein mean the elastic polymer or elastic polymer composition or the shaped article comprised of the elastic polymer or elastic polymer composition is characterized as having xylene extractables of less than or equal to 70 weight percent (that, is, greater than or equal to 30 weight percent gel content), preferably less than or equal to 40 weight percent (that is, greater than or equal to 60 weight percent gel content), more preferably less than or equal to 35 weight percent (that is; greater than or equal to 65 weight percent gel content), where xylene extractables (and gel content) are determined in accordance with ASTM D-2765.
[0029] The terms “cured” and “substantially cured” as used herein means the elastic polymer or elastic polymer composition or the shaped article comprised of the elastic polymer or elastic polymer composition was subjected or exposed to a treatment which induced crosslinking. As used herein, the terms also relate to the use of a grafted silane compound, e-beam and UV-radiation.
[0030] The terms “curable” and “crosslinkable” as used herein mean the elastic polymer or elastic polymer composition or the shaped article comprised of the elastic polymer or elastic polymer composition is not crosslinked and has not been subjected or exposed to treatment which induces crosslinking although the elastic polymer, elastic polymer composition or the shaped article comprised of the elastic polymer or elastic polymer composition comprises additive(s) or functionality that will effectuate crosslinking upon subjected or exposed to such treatment.
[0031] The term “pro-rad additive” as used herein means a compound which is not activated during normal fabrication or processing of the elastic polymer or elastic polymer composition, but can be activated by the application of temperatures (heat) substantially above normal fabrication or processing temperatures or ionizing energy (or both) (and especially with regard to article, part or item fabrication and processing) to effectuate some measurable gelation or preferably, substantial crosslinking.
[0032] In the practice of the present invention, curing, irradiation or crosslinking of the elastic polymers, elastic polymer compositions or articles comprising elastic polymers or elastic polymer compositions can be accomplished by any means known in the art, including, but not limited to, electron-beam irradiation, beta irradiation, X-rays, UV-radiation, controlled thermal heating, corona irradiation, peroxides, allyl compounds and gamma-radiation with or without crosslinking catalyst. Electron-beam and UV-radiation irradiation are the preferred technique for crosslinking the olefin polymer.
[0033] Preferably, the curing, irradiation, crosslinking or combination thereof provides a percent gel, as determined using xylene in accordance with ASTM D-2765, of greater than or equal to 30 weight percent, more preferably greater than or equal to 55 weight percent, most preferably greater than or equal to 60 weight percent. Suitable electron-beam irradiation equipment is available from Energy Services, Inc. Wilmington, Mass. with capabilities of at least 100 kilo-electron volts (KeV) and at least 5 kilowatts (Kw). Preferably, electrons are employed up to 70 megarads dosages. The irradiation source can be any electron beam generator operating in a range of 150 Kev to 12 mega-electron volts (MeV) with a power output capable of supplying the desired dosage. The electron voltage can be adjusted to appropriate levels which may be, for example, 100,000, 300,000, 1,000,000 or 2,000,000 or 3,000,000 or 6,000,000, or higher or lower. Many other apparati for irradiating polymeric materials are known in the art.
[0034] In the present invention, effective irradiation is usually carried out at a dosage between 3 megarads (Mrad) to megarads, preferably from 10 to 35 megarads, more preferably from 15 to 32 megarads, and most preferably from 19 to 28 megarads. Further, the irradiation can be conveniently carried out at room temperature. Preferably, irradiation is conducted while the article (or plurality of articles) is at lower temperatures throughout the exposure, such as, for example, at −50° C. to 40° C., especially at −20° C. to 30° C., more especially at 0° 0 C. to 25° C., and most especially from 0° C. to 12° C. The irradiation can be carried out on-line (that is, during fabrication of the article), off-line (such as after fabrication of the article, for example, film, by unwinding or wrapping the fabricated article) or on-spool (as such in the case of fibers, and filaments). Preferably, the irradiation is carried out after shaping or fabrication of the article. Also, in a preferred embodiment, a pro-rad additive is incorporated into the elastic polymer or elastic polymer composition and the polymer or composition is subsequently irradiated with electron beam radiation at 8 to 32 megarads.
[0035] In another aspect of the invention, the irradiation is carried out under an inert or oxygen-limited atmosphere. Suitable atmospheres can be provided by the use of helium, argon, nitrogen, carbon dioxide, xenon and/or a vacuum. Substantial improvements in high temperature serviceability can be gained by using an inert or oxygen-limited atmosphere without any attendant substantial lost in elastic performance ordinarily associated with service or use at elevated temperatures.
[0036] Crosslinking can be promoted with a crosslinking catalyst, and any catalyst that will provide this function can be used. Suitable catalysts generally include organic bases, carboxylic acids, and organometallic compounds including organic titanates and complexes or carboxylates of lead, cobalt, iron, nickel, zinc and tin. Dibutyltindilaurate, dioctyltinmaleate, dibutyltindiacetate, dibutyltindioctoate, stannous acetate, stannous octoate, lead naphthenate, zinc caprylate, and cobalt naphthenate. Tin carboxylate, especially dibutyltindilaurate and dioctyltinmaleate, are particularly effective for this invention. The catalyst (or mixture of catalysts) is present in a catalytic amount, typically between 0.015 and 0.035 phr.
[0037] Representative pro-rad additives include, but are not limited to, azo compounds, organic peroxides and polyfunctional vinyl or allyl compounds such as, for example, triallyl cyanurate, triallyl isocyanurate, pentaerthritol tetramethacrylate, glutaraldehyde, ethylene glycol dimethacrylate, diallyl maleate, dipropargyl maleate, dipropargyl monoallyl cyanurate, dicumyl peroxide, di-tert-butyl peroxide, t-butyl perbenzoate, benzoyl peroxide, cumene hydroperoxide, t-butyl peroctoate, methyl ethyl ketone peroxide, 2,5-dimethyl-2,5-di(t-butyl peroxy)hexane, lauryl peroxide, tert-butyl peracetate, and azobisisobutyl nitrite and combination thereof. Preferred pro-rad additives for use in the present invention are compounds which have polyfunctional (that is, at least two) moieties such as C═C, C═N or C═O.
[0038] At least one pro-rad additive can be introduced to the ethylene interpolymer by any method known in the art. However, preferably the pro-rad additives) is introduced via a masterbatch concentrate comprising the same or different base resin as the ethylene interpolymer. Preferably, the pro-rad additive concentration for the masterbatch is relatively high for example, greater than or equal to 25 weight percent (based on the total weight of the concentrate).
[0039] The at least one pro-rad additive is introduced to the ethylene polymer in any effective amount. Preferably, the at least one pro-rad additive introduction amount is from 0.001 20 to 5 weight percent, more preferably from 0.005 to 2.5 weight percent and most preferably from 0.015 to 1 weight percent (based on the total weight of the substantially hydrogenated block polymer).
[0040] Suitable amine or nitrogen-containing stabilizers for use in the present invention include, but are not limited to, naphthylamines, for example, N-phenyl naphthylamines such as Naugard PAN supplied by Uniroyal); diphenylamine and derivatives thereof which are also referred to as secondary aromatic amines (for example, 4,4′-bis (oc, oc-dimethylbenzyl) diphenylamine which is supplied by Uniroyal Chemical under the designation Naugard® 445); p-phenylenediamines (for example, Wingstay 300 supplied by Goodyear); piperidines and derivatives thereof (for example, poly[[6-[(1,1,3,3-tetramethylbutyl)amino]-1,3,5-triazine-2, 4-diyl][(2,2,6,6-tetramethyl-4-piperidinyl)imino)-1, 6-hexanediyl[(2,2,6,6-tetramethyl-4-piperidinyl)imino)]) which is supplied by Ciba Specialty Chemicals under the designation of Chimassorbe 944 as well as other substituted piperidines such as Chimassorb® 119, Tinuviri 622 and Tinuvin® 770, all three also supplied by Ciba Specialty Chemicals), and quinolines (for example, oxyquinolines and hydroquinolines such as polymeric 2,2,4-trimethyl-1,2-dihydroquinoline which is supplied by Vanderbilt Company under the designation Agerite® D).
[0041] Suitable amine or nitrogen-containing stabilizers also include the hybrid stabilizers such as aminophenols (for example, N,N′-hexamethylenebis-3-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionamide), acylaminophenols (which are also referred to as 4-hydroyanilides) and the various hybrid stabilizers described in U.S. Pat. No. 5,122,593 that consist of a N-(substituted)-1-(piperazine-2-one alkyl) group at one end and a (3,5-dialkyl-4-hydroxyphenyl)-α,α-disubstituted acetamine at the other end.
[0042] Other suitable amine or nitrogen-containing stabilizers include carboxylic acid amides of aromatic mono and dicarboxylic acids and N-monosubstituted derivatives (e.g N,N′-diphenylokamide and 2,2′-oxamidobisethyl-3-(3,5-di-tertbutyl-4-hydroxyphenyl)propionate which is supplied by Uniroyal Chemical under the designation Naugarde XL-1); hydrazides of aliphatic and aromatic mono- and dicarboxylic acids and N-acylated derivatives thereof; bis-acylated hydrazine derivatives; melamine; benzotriazoles, hydrazones; acylated derivatives of hydrazino-triazines; polyhydrazides; salicylaethylenediimines; salicylaloximes; derivatives of ethylenediamino tetraacetic acid; and aminotriazoles and acylated derivatives thereof.
[0043] Preferred amine or nitrogen-containing stabilizers for use in the present invention are diphenylamines, substituted piperidines and hydroquinolines. The most preferred amine or nitrogen-containing stabilizers are hindered amines since they tend to cause less detrimental polymer discoloration than aromatic amines.
[0044] Further, the at least one amine or nitrogen-containing stabilizer can be employed alone or in combination with one or more other stabilizer such as, for example, but not limited to, other amine or nitrogen-containing stabilizer; a hindered phenol (for example, 2,6-di-tert-butyl-4-methylphenol which is supplied by Koppers Chemical under the designation BHT; tetrakis(methylene 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate) methane which is supplied by Ciba Specialty Chemicals under the designation Irganox 1010; Irganox 1076 supplied by Ciba Specialty Chemicals; Cyanox 1790 which is tris (4-t-butyl-3-hydroxy=2,6-dimethylbenzyl)-s-triazine-2,4,6-(1H,3H,5H)-trione as supplied by Cytec; and Irganox 3114 which is 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)-1,3,5-triazinane-2,4,6-trione as supplied by Ciba Specialty Chemicals); a thioester (for example, dilauryl thiodipropionate which is supplied by Evans under the designation Evanstab® 12); a phosphite (for example, Irgafos® 168 supplied by Ciba Specialty Chemicals and tri(nonylphenyl) phosphite which is supplied by Uniroyal Chemical under the designation Naugard® P); diphosphite (for example, distearyl pentaerthritol diphosphite which is supplied by Borg-Warner under the designation Westori 618); a. polymeric phosphite (for example, Wytox. 345-S(1) supplied by Olin); phosphited phenol and bisphenol (for example, WytoX 604 supplied by Olin); and diphosphonite (for example, tetrakis(2,4-di-tert-butylphenyl) 4,4′-biphenylylene diphosphonite which is supplied by Sandos under the designation Sandostab® P-EPQ). A preferred combination is a hindered amine and a hindered phenol. With regard to hindered phenols, Cyanox 1790 and Irganox 3114 are preferred since these stabilizers tend to have a less detrimental effect on discoloration (due to nitroxide gas formation) than Irganox 1076 or Irganox 1010.
[0045] Preferably, the at least one amine or nitrogen-containing stabilizer (and optional other stabilizer) is added to the homogeneously branched ethylene polymer or the substantially hydrogenated block polymer or both in a melt compounding step, more preferably by the use of an additive concentrate, prior to fabrication and shaping process steps. The at least one nitrogen-containing stabilizer (and the optional other stabilizer) can be added to the interpolymer or block polymer at any effective concentration. But, preferably, the total stabilizer concentration is in the range of from 0.02 to 2 weight percent (based on the total weight of the stabilizer and interpolymer and/or block polymer), more preferably in the range from 0.075 to 1 weight percent (based on the total weight of the stabilizer and the interpolymer and/or block polymer) and most preferably in the range of from 0.1 to 0.32 weight percent (based on the total weight of the stabilizer and the interpolymer and/or block). Where an optional other stabilizer is used (for example, a hindered phenol), the concentration of the amine to the phenol is in-the range from 2:1 to 1:2, preferably in the range of from 1.25:1 to 1:1.25.
[0046] An especially preferred embodiment is a combination of amine with a phenol and a phosphorus-containing stabilizer, more preferably where the total concentration of the phenol and a phosphorus-containing stabilizer is less than or equal to 0.15 weight percent and the amine or nitrogen-containing stabilizer concentration is in the range of 0.15 to 0.32 weight percent.
[0047] In-process additives, for example, calcium stearate, water, and fluoropolymers, may-also be used for purposes such as for the deactivation of residual catalyst or improved processability or both. Colorants, coupling agents and fire retardants may also be include as longer as their incorporation does not disturb the desirable characteristics of the invention.
[0048] Suitable polymers for use in the present invention include ethylene-α-olefin interpolymers, substantially hydrogenated block polymers, styrene butadiene styrene block polymers, styrene-ethylenelbutene-styrene block polymers, ethylene styrene interpolymers, polypropylenes, polyamides, polyurethanes and any combination thereof. The preferred polymers are homogeneously branched ethylene-α olefin interpolymers.
[0049] The term “substantially hydrogenated block polymer” as used herein means a block copolymer that is characterized as having a hydrogenation level of greater than 90 percent (by number) for each vinyl aromatic monomer unit block and a hydrogenation level of greater than 95 percent (by number) for each conjugated diene polymer block, where for both the vinyl aromatic monomer and conjugated diene monomer repeating unit blocks, hydrogenation converts unsaturated moieties into saturated moieties. These polymers are more fully described in U.S. Ser. No. 09/627,534 filed on Jul. 28,2000.
[0050] The term “partially hydrogenated block polymer” as used herein means a block polymer that is hydrogenated but does not meet the hydrogenation levels that define a substantially hydrogenated block polymer.
[0051] Substantially hydrogenated block copolymers comprise at least one distinct block of a hydrogenated polymerized vinyl aromatic monomer and at least one block of a hydrogenated polymerized conjugated diene monomer. Preferred substantially hydrogenated block polymers are triblock comprising (before hydrogenation) two vinyl aromatic monomer unit blocks and one conjugated diene monomer unit block. Suitable substantially hydrogenated block polymers for use in the present invention are generally characterized by:
[0052] a) a weight ratio of conjugated diene monomer unit block to vinyl aromatic monomer unit block before hydrogenation of greater than 60:40
[0053] b) a weight average molecular weight (MW) before hydrogenation of from 30,000 to 150,000 (preferably, especially for high drawdown application such as, for example, fiber spinning, less than or equal to 81,000), wherein each vinyl aromatic monomer unit block (A) has a weight average molecular weight, Mwa, of from 5,000 to 45,000 and each conjugated diene monomer unit block (B) has a weight average molecular weight, Mwb, of from 12,000 to 110,000; and
[0054] c) a hydrogenation level such that each vinyl aromatic monomer unit block is hydrogenated to a level of greater than 90 percent and each conjugated diene monomer unit block is hydrogenated to a level of greater than 95 percent, as determined using UV-VIS spectrophotometry and proton NMR analysis.
[0055] Neat substantially hydrogenated block polymers can be further characterized as having a viscosity at 0.1 rad/sec and 190° C., as determined using a parallel plate rheometer (Rheometrics RMS-800 equipped with 25 mm diameter flat plates at 1.5 mm gap under a nitrogen purge), that is less than 1,000,000 poises, preferably less than or equal to 750,000 poises, more preferably less than 500,000 poises or that is at least 30 percent, preferably at least 50 percent, more preferably at least 80 lower than that of a partially hydrogenated block polymer having the same monomer types, number of monomer units, symmetry and weight average molecular weight, or that is defined by the following inequality:
[0000] Ln viscosity at 0.1 rad/sec # (7.08×10-5)( MW )+7.89
[0000] where “Ln” means natural log, and “#” means less than or equal to.
[0056] Neat substantially hydrogenated block polymers can also be further characterized as having a drawability of less than or equal to 200 denier, preferably less than or equal to 175 denier, more preferably less than or equal to 50 denier when fiber spun at 0.43 g/minute and 250° C. using an Instron capillary rheometer equipped with a die having a 1,000 micron diameter and a 20:1 L/D. The term “neat” is used herein to mean unblended with other synthetic polymer.
[0057] The vinyl aromatic monomer is typically a monomer of the formula:
[0000]
[0000] wherein R′ is hydrogen or alkyl, Ar is phenyl, halophenyl, alkylphenyl, alkylhalophenyl, naphthyl, pyridinyl, or anthracenyl, wherein any alkyl group contains 1 to 6 carbon atoms which may be mono or multisubstituted with functional groups such as halo, nitro, amino, hydroxy, cyano, carbonyl and carboxyl. More preferably Ar is phenyl or alkyl phenyl with phenyl being most preferred. Typical vinyl aromatic monomers include styrene, alpha-methylstyrene, all isomers of vinyl toluene, especially para-vinyl toluene, all isomers of ethyl styrene, propyl styrene, butyl styrene, vinyl biphenyl, vinyl naphthalene, vinyl anthracene and mixtures thereof. The block copolymer can contain more than one specific polymerized vinyl aromatic monomer. In other words, the block copolymer can contain a polystyrene block and a poly-α-methylstyrene block. The hydrogenated vinyl aromatic block may also be a copolymer, wherein the hydrogenated vinyl aromatic portion is at least 50 weight percent of the copolymer.
[0058] The conjugated diene monomer can be any monomer having 2 conjugated double bonds. Such monomers include for example 1,3-butadiene, 2-methyl-1,3-butadiene, 2-methyl-1,3-pentadiene, isoprene and similar compounds, and mixtures thereof. The block copolymer can contain more than one specific polymerized conjugated diene monomer. In other words, the block copolymer can contain a polybutadiene block and a polyisoprene block.
[0059] The conjugated diene polymer block can comprise materials that remain amorphous after the hydrogenation process, or materials which are capable of crystallization after hydrogenation. Hydrogenated polyisoprene blocks remain amorphous, while hydrogenated polybutadiene blocks can be either amorphous or crystallizable depending upon their structure. Polybutadiene can contain either a 1,2 configuration, which hydrogenates to give the equivalent of a 1-butene repeat unit, or a 1,4-configuration, which hydrogenates to give the equivalent of an ethylene repeat unit. Polybutadiene blocks having at least approximately 40 weight percent 1,2-butadiene content, based on the weight of the polybutadiene block, provides substantially amorphous blocks with low glass transition temperatures upon hydrogenation. Polybutadiene blocks having less than approximately 40 weight percent 1,2-butadiene content, based on the weight of the polybutadiene block, provide crystalline blocks upon hydrogenation. Depending on the final application of the polymer it may be desirable to incorporate a crystalline block (to improve solvent resistance) or an amorphous, more compliant block. In some applications, the block copolymer can contain more than one conjugated diene polymer block, such as a polybutadiene block and a polyisoprene block. The conjugated diene polymer block may also be a copolymer of a conjugated diene, wherein the conjugated diene portion of the copolymer is at least 50 weight percent of the copolymer. The conjugated diene polymer block may also be a copolymer of more than one conjugated diene, such as a copolymer of butadiene and isoprene. Also, other polymeric blocks may also be included in the substantially hydrogenated block polymers used in the present invention.
[0060] A “block” is herein defined as a polymeric segment of a copolymer which exhibits microphase separation from a structurally or compositionally different polymeric segment of the copolymer. Microphase separation occurs due to the incompatibility of the polymeric segments within the block copolymer. The separation of block segments can be detected by the presence of distinct glass transition temperatures. Microphase separation and block copolymers are generally discussed in “Block Copolymers-Designer Soft Materials”, PHYSICS TODAY, February, 1999, pages 32-38. Suitable substantially hydrogenated block polymers typically have a weight ratio of conjugated diene monomer unit block to vinyl aromatic monomer unit block before hydrogenation of from 60:40 to 95:5, preferably from 65:35 to 90:10, more preferably from 70:30 to 85:15, based on the total weight of the conjugated diene monomer unit and vinyl aromatic monomer unit blocks.
[0061] The total weights of the vinyl aromatic monomer unit block(s) and the conjugated diene monomer unit block(s) before hydrogenation is typically at least 80 weight percent, preferably at least 90, and more preferably at least 95 weight percent of the total weight of the hydrogenated block polymer. More specifically, the hydrogenated block polymer typically contains from 1 to 99 weight percent of a hydrogenated vinyl aromatic polymer (for example, polyvinylcyclohexane or PVCH block, generally from 10, preferably from 15, more preferably from 20, even more preferably from 25, and most preferably from 30 to 90 weight percent, preferably to 85 and most preferably to 80 percent, based on the total weight of the hydrogenated block polymer. And, as to the conjugated diene polymer block, the hydrogenated block copolymer typically contains from 1 to 99 weight percent of a hydrogenated conjugated diene polymer block, preferably from 10, more preferably from 15, and most preferably from 20 to 90 weight percent, typically to 85, preferably to 80, more preferably to 75, even more preferably to 70 and most preferably to 65 percent, based on the total weight of the copolymer.
[0062] The substantially hydrogenated block polymers suitable for use in the present invention are produced by the hydrogenation of block copolymers including triblock, multiblock, tapered block, and star block polymers such as, for example, but not limited to, SBS, SBSBS, SIS, SISIS, and SISBS (wherein S is polystyrene, B is polybutadiene and I is polyisoprene). Preferred block polymers contain at least one block segment comprised of a vinyl aromatic polymer block, more preferably the block polymer is symmetrical such as, for example, a triblock with a vinyl aromatic polymer block on each end. The block polymers may, however, contain any number of additional blocks, wherein these blocks may be attached at any point to the triblock polymer backbone. Thus, linear blocks would include, for example, SBS, SBSB, SBSBS, and SBSBSB. That is, suitable block polymers include asymmetrical block polymers and tapered linear block polymers. The block polymer can also be branched, wherein polymer chains are attached at any point along the polymer backbone. In addition, blends of any of the aforementioned block copolymers can also be used as well as blends of the block copolymers with their hydrogenated homopolymer counterparts. In other words, a hydrogenated SBS block polymer can be blended with a hydrogenated SBSBS block polymer or a hydrogenated polystyrene homopolymer or both. It should be noted here that in the production of triblock polymers, small amounts of residual diblock copolymers are often produced.
[0063] The weight average molecular weight (MW) of suitable substantially hydrogenated block polymers, as measured before hydrogenation, is generally from 30,000, preferably from 45,000, more preferably from 55,000 and most preferably from 60,000 to 150,000, typically to 140,000, generally to 135,000, preferably to 130,000, more preferably to 125,000, and most preferably to 120,000. But preferably, especially when used neat (that is, without being blended with other polymer) for fiber melt spinning purposes, the weight average molecular weight before hydrogenation will be less than or 20 equal to 81,500, more preferably less than or equal to 75,000 and most preferably less than or equal to 67,500. Substantially hydrogenated block polymers can have vinyl aromatic monomer unit block with weight average molecular weights, Mw, before hydrogenation of from 6,000, especially from 9,000, more-especially from 11,000, and most especially from 12,000 to 45,000, especially to 35,000, more especially to 25,000 and most especially to 20,000. The weight average molecular weight of the conjugated diene monomer unit block before hydrogenation can be from 12,000, especially from 27,000, more especially from 33,000 and most especially from 36,000 to 110,000, especially to 100,000, more especially to 90,000 and most especially to 80,000. But preferably, especially when used neat for fiber melt spinning purposes, for triblocks comprising two hydrogenated vinyl aromatic monomer unit blocks and one hydrogenated conjugated diene monomer unit block, the weight average molecular weight of each vinyl aromatic monomer unit block before hydrogenation will be less than or equal to 15,000, more preferably less than or equal to 13,000 and most preferably less than or equal to 12,000.
[0064] It is important to note that each individual block of the hydrogenated block copolymer of the present invention, can have its own distinct molecular weight. In other words, for example, two vinyl aromatic polymer blocks may each have a different molecular weight. Mp and MW, as used to throughout the specification, are determined using gel permeation chromatography (GPC). The molecular weight of the substantially hydrogenated block polymer and properties obtained are dependent upon the molecular weight of each of the monomer unit blocks. For substantially hydrogenated block polymers, molecular weights are determined by comparison to narrow polydispersity homopolymer standards corresponding to the different monomer unit segments (for example, polystyrene and polybutadiene standards are used for SBS block copolymers) with adjustments based on the composition of the block copolymer. Also for example, for a triblock copolymer composed of styrene (S) and butadiene (B), the copolymer molecular weight can be obtained by the following equation:
[0000] In Mc=x 1 nMa+ (1 −x ) In Mb
[0000] where Mc is the molecular weight of the copolymer, x is the weight fraction of S in the copolymer, Ma is the apparent molecular based on the calibration for S homopolymer and Mb is the apparent molecular weight based on the calibration for homopolymer B. This method is described in detail by L. H. Tung, Journal of Applied Polymer Science, volume 24, 953, 1979.
[0065] Methods of making block polymers are well known in the art. Typically, block polymers are made by anionic polymerization, examples of which are cited in Anionic Polymerization Principles and Practical Applications, H. L. Hsieh and R. P. Quirk, Marcel Dekker, New York, 1996. Block polymers can be made by sequential monomer addition to a carbanionic initiator such as sec-butyl lithium or n-butyl lithium. Block polymers can also be made by coupling a triblock material with a divalent coupling agent such as 1,2-dibromoethane, dichlorodimethylsilane, or phenylbenzoate. In this method, a small chain (less than 10 monomer repeat units) of a conjugated diene monomer can be reacted with the vinyl aromatic monomer unit coupling end to facilitate the coupling reaction. Note, however, vinyl aromatic polymer blocks are typically difficult to couple, therefore, this technique is commonly used to achieve coupling of the vinyl aromatic polymer ends. The small chain of the conjugated diene monomer unit does not constitute a distinct block since no microphase separation is achieved.
[0066] Coupling reagents and strategies which have been demonstrated for a variety of anionic polymerizations are discussed in Hsieh and Quirk, Chapter 12, pgs. 307-331. In another method, a difunctional anionic initiator is used to initiate the polymerization from the center of the block system, wherein subsequent monomer additions add equally to both ends of the growing polymer chain. An example of a such a difunctional initiator is 1,3-bis(1-phenylethenyl) benzene treated with organolithium compounds, as described in U.S. Pat. No. 4,200,718 and 4,196,154.
[0067] After preparation of the block polymer, the polymer is hydrogenated to remove sites of unsaturation in both the conjugated diene monomer unit block(s) and the vinyl aromatic monomer unit block(s) of the polymer. Any method of hydrogenation can be used where suitable methods typically include the use of metal catalysts supported on an inorganic substrate, such as Pd on BaSO 4 (U.S. Pat. No. 5,352,744) and Ni on kieselguhr (U.S. Pat. No. 3,333,024). Additionally, soluble, homogeneous catalysts such those prepared from combinations of transition metal salts of 2-ethylhexanoic acid and alkyl lithiums can be used to fully saturate block copolymers, as described in Die Makromolekulare Chemie, Volume 160, pp. 291, 1972. Hydrogenation can also be achieved using hydrogen and a heterogeneous catalyst such as those described in U.S. Pat. No. 5,352,744; 5,612,422 and 5,645,253. The catalysts described therein are heterogeneous catalysts consisting of a metal crystallite supported on a porous silica substrate. An example of a silica supported catalyst which is especially useful in the polymer hydrogenation is a silica which has a surface area of at least 10 m 2 /g which is synthesized such that it contains pores with diameters ranging between 3000 and 6000 angstroms. This silica is then impregnated with a metal capable of catalyzing hydrogenation of the polymer, such as nickel, cobalt, rhodium, ruthenium, palladium, platinum, other Group VIII metals, combinations or alloys thereof. Other heterogeneous catalysts can also be used, having average pore diameters in the range of 500 to 3,000 angstroms.
[0068] The level of hydrogenation of the substantially hydrogenated block polymers used in the present invention is greater than 95 percent for the conjugated diene monomer unit block(s) and greater than 90 percent for the vinyl aromatic monomer unit block(s), preferably greater than 99 percent for the conjugated diene monomer unit block(s) and greater than 95 percent for the vinyl aromatic monomer unit block(s), more preferably greater than 99.5 percent for the conjugated diene monomer unit block(s) and greater than 98 percent for the vinyl aromatic monomer unit block(s), and most preferably greater than 99.9 percent for the conjugated diene monomer unit block(s) and 99.5 percent for the vinyl aromatic monomer unit block(s).
[0069] The term “level of hydrogenation” refers to the percentage of the original unsaturated bonds that become saturated upon hydrogenation. The level of hydrogenation for the (hydrogenated) vinyl aromatic monomer unit block(s) can be determined using gamma-VIS spectrophotometry, while the level of hydrogenation for the (hydrogenated) diene conjugated monomer unit block(s) can be determined using proton NMR. The block polymer composition (that is, ratio of conjugated diene monomer unit blocks to vinyl aromatic monomer unit blocks) can be determined using proton NMR and a comparative integration technique such as that described by Santee, Chang and Morton in Journal of Polymer Science: Polymer Letter Edition, Vol. 11, page 449 (1973). Conveniently,, a Varian Inova NMR unit set at 300 MHz for 1 H is used and samples of the block polymer are analyzed as 4 percent solutions (w/v) in CDC13 (deuterochloroform). Individual block lengths can be calculated from the weight average molecular weight, Mw, and 1 H NMR compositional analysis and by assuming a symmetrical structure (for example, a triblock with terminal polystyrene blocks).
[0070] The term “homogeneously branched ethylene polymer” is used herein in the conventional sense to refer to an ethylene interpolymer in which the comonomer is randomly distributed within a given polymer molecule and wherein substantially all of the polymer molecules have the same ethylene to comonomer molar ratio. The term refers to an ethylene interpolymer that are manufactured using so-called homogeneous or single-site catalyst systems known in the art such Ziegler vanadium, hafnium and zirconium catalyst systems and metallocene catalyst systems for example, a constrained geometry catalyst systems which is further described herein below.
[0071] Homogeneously branched ethylene polymers for use in the present invention can be also described as having less than 15 weight percent, preferably less 10 weight percent, more preferably less than 5 and most preferably zero (0) weight percent of the polymer with a degree of short chain branching less than or equal to 10 methyls/1000 carbons. That is, the polymer contains no measurable high density polymer fraction (for example, there is no fraction having a density of equal to or greater than 0.94 g/cm3), as determined, for example, using a temperature rising elution fractionation (TREF) technique and infrared or 13 C nuclear magnetic resonance (NMR) analysis.
[0072] Preferably, the homogeneously branched ethylene polymer is characterized as having a narrow, essentially single melting TREF profile/curve and essentially lacking a measurable high density polymer portion, as determined using a temperature rising elution fractionation technique (abbreviated herein as “TREF”). The composition distribution of an ethylene interpolymer can be readily determined from TREE as described, for example, by Wild et al., Journal of Polymer Science, Poly. Phys. Ed., Vol. 20, p. 441 (1982), or in U.S. Pat. No. 4,798,081 and 5,008,204; or by L. D. Cady, “The Role of Comonomer Type and Distribution in LLDPE Product Performance,” SPE Regional Technical Conference, Quaker Square Hilton, Akron, Ohio, October 1-2, pp. 107-119 (1985).
[0073] The composition (monomer) distribution of the interpolymer can also be determined using 13 C NMR analysis in accordance with techniques described in U.S. Pat. No. 5,292,845; U.S. Pat. No. 4,798,081; U.S. Pat. No. 5,089,321 and by J. C. Randall, Rev. Macromol. Chem. Phys., C29, pp. 201-317 (1989). In analytical temperature rising elution fractionation analysis (as described in U.S. Pat. No. 4,798,081 and abbreviated herein as “ATREF”), the polymer, polymer composition or article to be analyzed is dissolved in a suitable hot solvent (for example, trichlorobenzene) and allowed to crystallized in a column containing an inert support (stainless steel shot) by slowly reducing the temperature. The column is equipped with both a refractive index detector and a differential viscometer (DV) detector. An ATREF-DV chromatogram curve is then generated by eluting the crystallized polymer sample from the column by slowly increasing the temperature of the eluting solvent (trichlorobenzene). The ATREF curve is also frequently called the short chain branching distribution (SCBD) or composition distribution (CD) curve, since it indicates how evenly the comonomer (for example, 1-octene) is distributed throughout the sample in that as elution temperature decreases, comonomer content increases. The refractive index detector provides the short chain distribution information and the differential viscometer detector provides an estimate of the viscosity average molecular weight. The composition distribution and other compositional information can also be determined using crystallization analysis fractionation such as the CRYSTAF fractionalysis package available commercially from PolymerChar, Valencia, Spain.
[0074] Preferred homogeneously branched ethylene polymers (such as, but not limited to, substantially linear ethylene polymers) have a single melting peak between −30 and 150° C., as determined using differential scanning calorimetry (DSC), as opposed to traditional Ziegler polymerized heterogeneously branched ethylene polymers (for example, LLDPE and ULDPE or VLDPE) which have two or more melting points. The single melting peak is determined using a differential scanning calorimeter standardized with indium and deionized water. The method involves about 5-7 mg sample sizes, a “first heat” to about 180° C. which is held for 4 minutes, a cool down at 10° C./min. to −30° C. which is held for 3 minutes, and heat up at 10° C./min. to 150° C. to provide a “second heat” heat flow vs. temperature curve from which the melting peak(s) is obtained. Total heat of fusion of the polymer is calculated from the area under the curve.
[0075] The at least one homogeneously branched ethylene interpolymer to be irradiated and/or crosslinked has a density at 23° C. less than 0.90 g/cm 3 , preferably less than or equal to 0.88 g/cm 3 , more preferably less than or equal to 0.87 g/cm 3 , and especially in the range of 0.86 g/cm 3 to 0.875 g/cm 3 , as measured in accordance with ASTM D792. Preferably, the homogeneously branched ethylene interpolymer is characterized as having a melt index less than 100 g/10 minutes, more preferably less than 30, most preferably less than 10 g/10 minutes or in the range of 3 to 12 g/10 minutes, as determined in accordance with ASTM D-1238, Condition 190° C./2.16 kilogram (kg). ASTM D-1238, Condition 190° C./2.16 kilogram (kg) are referred to herein as I 2 melt index.
[0076] The homogeneously branched ethylene polymers for use in the invention can be either a substantially linear ethylene polymer or a homogeneously branched linear ethylene polymer. The term “linear” as used herein means that the ethylene polymer does not have long chain branching. That is, the polymer chains comprising the bulk linear ethylene polymer have an absence of long chain branching, as in the case of traditional linear low density polyethylene polymers or linear high density polyethylene polymers made using Ziegler polymerization processes (for example, U.S. Pat. No. 4,076,698), sometimes called heterogeneous polymers. The term “linear” does not refer to bulk high pressure branched polyethylene, ethylene/vinyl acetate copolymers, or ethylene/vinyl alcohol copolymers which are known to those skilled in the art to have numerous long chain branches.
[0077] The term “homogeneously branched linear ethylene polymer” refers to polymers having a narrow short chain branching distribution and an absence of long chain branching. Such “linear” uniformly branched or homogeneous polymers include those made as described, for example, in U.S. Pat. No. 3,645,992 and those made, for example, using so called single site catalysts in a batch reactor having relatively high ethylene concentrations (as described in U.S. Pat. Nos. 5,026,798 or 5,055,438) or those made using vanadium catalysts or those made using constrained geometry catalysts in a batch reactor also having relatively high olefin concentrations (as described in U.S. Pat. No. 5,064,802 or in EP 0 416 815 A2).
[0078] Typically, homogeneously branched linear ethylene polymers are ethylene/α-olefin interpolymers, wherein the α-olefin is at least one C 3 -C 20 α-olefin (for example, propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-heptene, 1-hexene, and 1-octene) and preferably the at least one C 3 -C 20 α-olefin is 1-butene, 1-hexene, 1-heptene or 1 octene. Most preferably, the ethylene/α-olefin interpolymer is a copolymer of ethylene and a C 3 -C 20 α-olefin, and especially an ethylene/C 4 -C 8 α-olefin copolymer such as an ethylene/1-octene copolymer, ethylene/1-butene copolymer, ethylene/1-pentene copolymer or ethylene/1-hexene copolymer. Suitable homogeneously branched linear ethylene polymers for use in the invention are sold under the designation of TAFMER by Mitsui Chemical Corporation and under the designations of EXACT and EXCEED resins by Exxon Chemical 5 Company.
[0079] The term “substantially linear ethylene polymer” as used herein means that the bulk ethylene polymer is substituted, on average, with 0.01 long chain branches/1000 total carbons to 3 long chain branches/1000 total carbons (wherein “total carbons” includes both backbone and branch carbons). Preferred polymers are substituted with 0.01 long chain branches/1000 total carbons to 1 long chain branches/1000 total carbons, more preferably from 0.05 long chain branches/1000 total carbons to 1 long chain branched/1000 total carbons, and especially from 0.3 long chain branches/1000 total carbons to 1 long chain branches/1000 total carbons.
[0080] As used herein, the term “backbone” refers to a discrete molecule, and the term “polymer” or “bulk polymer” refers, in the conventional sense, to the polymer as formed in a reactor. For the polymer to be a “substantially linear ethylene polymer”, the polymer must have at least enough molecules with long chain branching such that the average long chain branching in the bulk polymer is at least an average of from 0.01/1000 total carbons to 3 long chain branches/1000 total carbons. The term “bulk polymer” as used herein means the polymer which results from the polymerization process as a mixture of polymer molecules and, for substantially linear ethylene polymers, includes molecules having an absence of long chain branching as well as molecules having long chain branching. Thus a “bulk polymer” includes all molecules formed during polymerization. It is understood that, for the substantially linear polymers, not all molecules have long chain branching, but a sufficient amount do such that the average long chain branching content of the bulk polymer positively affects the melt rheology (that is, the shear viscosity and melt fracture properties) as described herein below and elsewhere in the 5 literature.
[0081] Long chain branching (LCB) is defined herein as a chain length of at least one (1) carbon less than the number of carbons in the comonomer, whereas short chain branching (SCB) is defined herein as a chain length of the same number of carbons in the residue of the comonomer after it is incorporated into the polymer molecule backbone. For example, a substantially linear ethylene/1-octene polymer has backbones with long chain branches of at least seven (7) carbons in length, but it also has short chain branches of only six (6) carbons in length.
[0082] The substantially linear ethylene polymers used in the present invention are a unique class of compounds that are further defined in U.S. Pat. Nos. 5,272,236, 5,278,272 and 5,665,800. The substantially linear ethylene elastomers and plastomers for use in the present invention are further characterized as having:
[0083] (a) melt flow ratio, I 10 /I 2 ≧5.63,
[0084] (b) a molecular weight distribution, Mw/Mn, as determined by gel permeation chromatography and defined by the equation: (Mw/Mn)≦(I 10 /I 2 )−4.63,
[0085] (c) a gas extrusion rheology such that the critical shear rate at onset of surface melt fracture for the substantially linear ethylene polymer is at least 50 percent greater than the critical shear rate at the onset of surface melt fracture for a linear ethylene polymer, wherein the substantially linear ethylene polymer and the linear ethylene polymer comprise the same comonomer or comonomers, the linear ethylene polymer has an I 2 and Mw/Mn within ten percent of the substantially linear ethylene polymer and wherein the respective critical shear rates of the substantially linear ethylene polymer and the linear ethylene polymer are measured at the same melt temperature using a gas extrusion rheometer,
[0086] (d) a single differential scanning calorimetry, DSC, melting peak between −30 and 150 C, and
[0087] (e) a density less than or equal to 0.895 g/cm 3 .
[0000] Determination of the critical shear rate and critical shear stress in regards to melt fracture as well as other rheology properties such as “rheological processing index” (PI), is performed using a gas extrusion rheometer (GER). The gas extrusion rheometer is described by M. Shida, R. N. Shroff and L. V. Cancio in Polymer Engineering Science, Vol. 17, No. 11, p. 770 (1977) and in Rheometers for Molten Plastics by John Dealy, published by Van Nostrand Reinhold Co. (1982) on pp. 97-99.
[0088] An apparent shear stress vs. apparent shear rate plot is used to identify the melt fracture phenomena over a range of nitrogen pressures from 5250 to 500 psig (369 to 35 kg /cm 2 ) using the die or GER test apparatus previously described.
[0089] The molecular weights and molecular weight distributions are determined by gel permeation chromatography (GPC). A suitable unit is a Waters 150 C high temperature chromatographic unit equipped with a differential refractometer and three columns of mixed porosity where columns are supplied by Polymer Laboratories and are commonly packed with pore sizes of 10 3 , 10 3 , 10 5 and 10 6 A. For ethylene polymers, the unit operating temperature is about 140° C. and the solvent is 1,2,4-trichlorobenzene, from which about 0.3 percent by weight solutions of the samples are prepared for injection. Conversely, for the substantially hydrogenated block polymers, the unit operating temperature is about 25° C. and tetrahydrofuran is used as the solvent. A suitable flow rate is about 1.0 milliliters/minute and the 5 injection size is typically about 100 microliters.
[0090] For the ethylene polymers where used in the present invention, the molecular weight determination with respect to the polymer backbone is deduced by using narrow molecular weight distribution polystyrene standards (from Polymer Laboratories) in conjunction with their elution volumes. The equivalent polyethylene molecular weights are determined by using appropriate Mark-Houwink coefficients for polyethylene and polystyrene (as described by Williams and Ward in Journal of Polymer Science, Polymer Letters, Vol. 6, p. 621, 1968) to derive the following equation:
[0000] M polyethylene −a* ( M polystyrene ) b
[0000] In this equation, a=0.4316 and b=1.0. Weight average molecular weight, Mw, is calculated in the usual manner according to the following formula:
[0000] M j =( w i ( M i j )) j
[0000] where wi is the weight fraction of the molecules with molecular weight Mi eluting from the GPC column in fraction i, and j=1 when calculating Mw and j=−1 when calculating Mi j . For the at least one homogeneously branched ethylene polymer used in the present invention, the M w /M n is preferably less than 3.5, more preferably less than 3.0, most preferably less than 2.5, and especially in the range of from 1.5 to 2.5 and most especially in the range from 1.8 to 2.3.
[0091] The homogeneously branched ethylene interpolymers (for example, substantially linear ethylene polymers and homogeneously branched linear ethylene polymers) used in the present invention are interpolymers of ethylene with at least one C 3 -C 20 α-olefin and/or C 4 -C 12 diolefin. Copolymers of ethylene and an -olefin of C 3 -C 20 carbon atoms are especially preferred. The term “interpolymer” as discussed above is used herein to indicate a copolymer, or a terpolymer, where, at least one other comonomer is polymerized with ethylene or propylene to make the interpolymer. Suitable unsaturated comonomers useful for polymerizing with ethylene include, for example, ethylenically unsaturated monomers, conjugated or non-conjugated dienes, polyenes, etc. Examples of such comonomers include C 3 -C 20 α-olefins such as propylene, isobutylene, 1-butene, 1-hexene, 1-pentene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-nonene, and 1-decene. Preferred comonomers include propylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-heptene, and 1-octene, and 1-octene is especially preferred. Other suitable monomers include styrene, halo- or alkyl-substituted styrenes, vinylbenzocyclobutane, 1,4-hexadiene, 1,7-octadiene, and naphthenics (for example, cyclopentene, cyclohexene and cyclooctene).
[0092] In one preferred embodiment, at least one substantially hydrogenated block polymer is blended with at least one substantially linear ethylene polymer. In another preferred embodiment, at least one substantially hydrogenated block polymer is blended with at least one polypropylene polymer. Suitable polypropylene polymers for use in the invention, including random block propylene ethylene polymers, are available from a number of manufacturers, such as, for example, Montell Polyolefins and Exxon Chemical Company. From Exxon, suitable polypropylene polymers are supplied under the designations ESCORENE and ACHIEVE.
[0093] Other polymers that can be blended with either the substantially hydrogenated block polymer or the homogeneously branched ethylene interpolymer include, for example, but are not limited to, substantially hydrogenated block polymers, styrene block polymers, substantially linear ethylene polymers, homogeneously branched linear ethylene polymers, heterogeneously branched linear ethylene (including linear low density polyethylene (LLDPE), ultra or very low density polyethylene (ULDPE or VLDPE) medium density polyethylene (MDPE) and high density polyethylene (HDPE)), high pressure low density polyethylene (LDPE), ethylene/acrylic acid (EAA) copolymers, ethylene/methacrylic acid (EMAA) copolymers, ethylene/acrylic acid (EAA) ionomers, ethylene/methacrylic acid (EMAA) ionomers, ethylene/vinyl acetate (EVA) copolymers, ethylene/vinyl alcohol (EVOH) copolymers, polypropylene homopolymers and copolymers, ethylene/propylene polymers, ethylene/styrene interpolymers, graft-modified polymers (for example, maleic anhydride grafted polyethylene such as LLDPE g-MAH), ethylene acrylate copolymers (for example, ethylene/ethyl acrylate (EEA) copolymers, ethylene/methyl acrylate (EMA), and ethylene/methmethyl acrylate (EMMA) copolymers), polybutylene (PB), ethylene carbon monoxide interpolymer (for example, ethylene/carbon monoxide (ECO), copolymer, ethylene/acrylic acid/carbon monoxide (EAACO) terpolymer, ethylene/methacrylic acid/carbon monoxide (EMAACO) terpolymer, ethylene/vinyl acetate/carbon monoxide (EVACO) terpolymer and styrene/carbon monoxide (SCO)), chlorinated polyethylene and mixtures thereof.
[0094] The following examples are to illustrate the invention, and not to limit it. Ratios, parts and percentages are by weight unless otherwise stated.
EXPERIMENTAL
[0000]
Fiber Descriptions:
Fiber made from Dow AFFINITY ethylene-octene copolymer (MI 3 g/10 min, density 0.875 g/cc) 140 Denier crosslinked by e-beam (19.2 mrad)
Generic spandex
Fabric Description:
3×1 RHT (right-hand twill); 100% cotton warp, 94% cotton/6% Crosslinked AFFINITY filling.
Example 1
Stone Washing
[0100] The stones were white pumas ranging approximately between 2-4 inches in diameter. The stones were soaked in the chemical solution for two (2) hours prior to testing.
[0000]
Stone Wash/Decolorize - Hypochlorite Formula
Liquor
Water
Time
Chemical
Process
Ratio
Temp (F.)
(Min)
Quantity
Chemical
Comment
Stonewash/
10:1
140
90
10% soln. 5.25%
Sodium
3:1 Stone to
Hypochlorite
available Cl
Hypochlorite
Fabric ratio
(stone soak)
Drain/Rinse
10:1
170
10
Rinse
Neutralize
10:1
170
20
0.5 g/l
Sodium
Disulfite
Drain/rinse
Rinse Hot
Rinse Cold
Dry
Tumble Dry
Low
[0000]
Stone Wash/Decolorize - Permanganate Formula
Liquor
Water
Time
Chemical
Process
Ratio
Temp (F.)
(Min)
Quantity
Chemical
Comment
Stonewash/
10:1
140
90
5% soln. (stone
Potassium
3:1 Stone to
Potassium
soak)
Permanganate
Fabric ratio
Permanganate
Drain/Rinse
10:1
170
10
Rinse
Neutralize
10:1
170
20
0.5 g/l
Sodium
Bisulfite
Drain/rinse
Rinse Hot
Rinse Cold
Dry
Tumble Dry
Low
Test Results:
[0101] To understand the effects of stone washing on spandex, a sample of stretch denim comprising spandex was run in parallel with a sample of stretch denim comprising AFFINITY fiber. Although the properties of the two fabrics cannot be compared directly (the fabrics are of slightly different constructions), the data does show, however, property degradation in spandex-based denims and property retention in AFFINITY-based denims.
[0000]
AFFINITY
Spandex
Denim
Denim
Test Procedures
Length
Width
Length
Width
Fabric Dimensional Change
−2.2%
−1.6%
4.9%
−10.2%
(AATCC 135) After Stone Wash,
Chlorine Bleach
Fabric Dimensional Change
−2.6%
−1.7%
−5.1%
−10.5%
(AATCC 135) After Stone Wash,
Permanganate
Stretch and Recovery
Stretch
Growth
Stretch
Growth
Comparison (ASTM D6614)
As Received
7.0%
2.9%
17.3%
4.5%
After 1x Stone Wash, Chlorine
7.3%
3.5%
28.3%
8.0%
Bleach
After 1x Stone Wash,
7.5%
3.5%
29.9%
10.1%
Permanganate
[0102] Denim fabric containing AFFINITY fiber did not have any significant change in stretch properties. When a commercially available spandex containing stretch fabric was subjected to the hypochlorite and permangenate washes, it exhibited deterioration in stretch properties and 5 dimensional stability.
Example 2
Stripping Agents
[0000]
Chemical Reduction by 1 g/L Sodium Hydrosulfite (Dye Stripping), 100° C./212° F., 1 hour:
[0104] Dye Stripping is a process to chemically remove color from fabric for redying. This test was performed as sodium hydrosulfite is a commonly used dye stripping agent. Since published research has shown some sensitivity on the part of elastomeric fibers to dye-stripping. Dyers prefer to work with a fiber that can withstand a stripping bath rather than one that will not.
[0105] Fiber Description:
[0106] Fiber made from Dow AFFINITY EG 8200 (MI 5 g/10 min, density 0.870 g/cc) 70 Denier crosslinked by e-beam (32 mrad)
[0107] Dupont Lycra 70 Denier
[0108] Dupont Lycra - Chlorine Resistant 70 Denier
[0000]
Fiber Test Data
AFFINITY
Lycra
Lycra-CR
Ultimate Elongation
276.68
334.94
297.26
After Treatment (%)
% Difference against
−16%
−23%
−28%
as received
Breaking Load After
32.35
49.21
47.37
Treatment (g)
% Difference against
−53
−43
−33
as received
Example 3
Swimming Pool Water
[0000]
100 ppm Sodium Hypochlorite (Chlorine Bleach), 50° C./120° F., 24 hours:
[0110] This accelerated test was performed as the hypochlorite ion is responsible both for bleaching and fiber damage in textiles, and it is also a chief cause in the degradation of fibers by swimming pool water. This level of chlorine was found by ruggedness testing to be roughly equivalent to the amount of exposure that would cause failure in a chlorine resistant Lycra® swimsuit after five months of use in which the suit was worn three times per week.
[0111] Fiber description: P Fiber made from Dow AFFINITY EG 8200 (MI 5 g/10 min, density 0.870 g/cc) 70 Denier crosslinked by e-beam (32 mrad)
[0112] Dupont Lycra 70 Denier
[0113] Dupont Lycra—Chlorine Resistant 70 Denier
[0000]
AFFINITY
Lycra
Lycra-CR
Ultimate Elongation
250.23
125.83
206.50
After Treatment (%)
% Difference against
−24%
−71%
−50%
as received
Breaking Load After
38.46
2.12
15.19
Treatment (g)
% Difference against
−44%
−98%
−79%
as received
Example 4
Wear Test
[0114] Fiber description:
Fiber made from Dow AFFINITY EG 8200 (MI 5 g/10 min, density 0.870 g/cc) 70 Denier crosslinked by e-beam (32 mrad)
[0116] A Speedo suit made of a two bar tricot construction with nylon and conventional Lycra spandex was obtained that displayed almost complete disintegration of the spandex component. Additionally new Speedo suits containing chlorine resistant Lycra spandex were purchased, and a swimsuit was constructed using weft knit polyester (about 88% by weight)/Dow AFFINITY fiber (about 12% by weight) fabric.
[0117] After a five-month wear trial test, the chlorine resistant suit displayed localized degradation. Scanning Electron Microscopy (SEM) images ( FIGS. 2 and 3 ) revealed that this degradation involved only the spandex filaments which were heavily degraded while the nylon filaments were untouched.
[0118] In contrast to the chlorine resistant spandex, the crosslinked AFFINITY elastomeric yam contained in a similar swimsuit used in a four month wear trial displayed no degradation ( FIGS. 4 and 5 ). No significant bagging of the AFFINITY suit was found present and the suit was found to be functional in all ways with exception of the polyester yarn's propensity to stain readily when exposed to zinc oxide sun block, sun tan lotion and oil.
[0119] After completion of the wear trial, the AFFINITY suit was washed using the machine wash/warm tumble dry low cycle. The suit improved in appearance due to removal of stains and dirt accumulated over the period of the wear trial. After washing, the suit continued to fit well without bagging or excess shrinkage.
Example 5
Laundering
[0000]
Stretch Properties of Fabric Containing AFFINITY Crosslinked Fibers:
Fabric description: 3×1 LHT (left-hand twill); 100% Nylon T-66 warp, 84% cotton/16% Dow AFFINITY EG 8200 (MI 5 g/10 min, density 0.870 g/cc) 70 Denier crosslinked by e-beam (22.4 mrad) filling.
[0000]
Fabric Stretch, % weft direction
Laundry
(ASTM-D-6614-00)
Method
Conditions
1 cycle
25 cycles
50 cycles
MWH TDH SIM
From AATCC Test Method 135
66.6
70.2
73.0
machine wash hot
(normal cycle, 12 minutes), 140° F.
tumble dry high, 160° F.
steam iron medium, 300° F.
MWH TDH SIM
From AATCC Test Method 135
65.0
70.1
74.6
With Chlorine
machine wash hot
(CLOROX ®)
(normal cycle, 12 minutes), 140° F.
tumble dry high, 160° F.
steam iron medium, 300° F.
MWH TDH SIM
From AATCC Test Method 135
64.1
66.4
71.0
With Non-
machine wash hot
Chlorine Bleach
(normal cycle, 12 minutes), 140° F.
(CLOROX 2 ®)
tumble dry high, 160° F.
steam iron medium, 300° F.
[0122] The data in the above table demonstrates that the fabric experiences minimal change over 1 to 50 cycles.
[0123] Although the invention has been described in considerable detail through the preceding embodiments, this detail is for the purpose of illustration. Many variations and modifications can be made on this invention without departing from the spirit and scope of the invention as described in the following claims. All U.S. patents and allowed U.S. patent applications cited above are incorporated herein by reference. | Durable stretch fabrics are made and processed from one or more crosslinked, heat-resistant olefin elastic fibers, e.g., a substantially linear, homogeneously branched ethylene polymer. The fabrics can be made by any process, e.g., weaving, knitting, etc., and from any combination of crosslinked, heat-resistant olefin elastic and inelastic (“hard”) fibers, e.g., cotton and wool. These fabrics exhibit excellent chemical, e.g., chlorine, resistance and durability, e.g., they retain their shape and feel (“hand”) over repeated exposure to processing conditions, e.g., stone-washing, dye-stripping, PET-dyeing and the like, and service conditions, e.g., washing, drying, etc. | 3 |
This is a continuation-in-part of application Ser. No. 08/069,896, filed Jun. 1, 1993.
FIELD OF THE INVENTION
The present invention relates to a system used in pouring molten metal and, more particularly, to a system that reduces slag vortexing which can occur during the outflow of molten metal from a tundish or a ladle using a slide gate valve or stopper rod for flow control. The reduction of slag vortexing advantageously results in a higher percentage of metal that is substantially free of slag.
BACKGROUND OF THE INVENTION
Molten metal is often dispensed from a bottom discharge pouring and holding reservoir, sometimes referred to as either a tundish or simply a box, into a mold. The tundish is usually kept supplied with molten metal from a ladle. The purity of the metal being discharged from the tundish is important to successfully cast clean metal into the mold. More particularly, the poured metal should be free of slag that forms on the surface of molten metal and also free of bubbles that are sometimes created and entrained in the metal during the pouring process. If the output flow of molten metal from the ladle entrains any slag or any other unwanted inclusion, the quality of the cast metal is degraded. A major contributor to this degradation is the occurrence of vortexing, in the form of whirlpools, created during the pouring operation as a result of Coriolis forces on the flowing metal.
If slag is drawn by a vortex into the stream of molten metal being poured into a tundish or pouring box, it can easily become trapped in the end product. Further, if the stream of molten metal being poured into the mold is spiraling when it exits the bottom nozzle of the reservoir, the stream may become hollow and enlarged so as to expose much of its lateral surface to the atmosphere. If this exposure occurs, the metal may be reoxidized which, in turn, results in a significant loss of quality in the cast product. Products of reoxidation sometimes get trapped in the solidified cast metal and are generally referred to as dirt.
The danger of slag contamination is almost always present because, as metal is melted, a slag is formed on the surface of the molten metal. However, so long as the slag remains on the top surface, it does not present a problem for successful casting. Unfortunately, and typically, when pouring a batch of steel, slag begins to be vortexed into the output flow of the molten metal from the ladle into the tundish and will undesirably find its way into the mold. The presence, or even the danger of such slag being present in the tundish, commonly causes the pouring process to be terminated. For these situations, as much as two to four percent of the metal may still be left in a ladle, and this amount is treated as scrap to be recycled by being remelted. Remelting of this metal results in an additional, undesired cost. It is thus desired to reduce the vortexing of slag from the ladle into the tundish, especially to reduce the need to remelt these large quantities of metal, so as to decrease costs.
The drawbacks of vortexing are present in both continuous casting and ingot pouring operations. In continuous casting, the molten metal continuously flows out of the orifice of a nozzle and onto a mold to form a continuous shape, such as a steel billet, bloom, slab or strip. In non-continuous casting, the flow of molten metal is stopped after an ingot mold is filled, and then re-started when a new ingot mold is in place.
For continuous casting, it is known that undesired vortexing and spiraling may be reduced by the placement of flutes in the orifice of the nozzle (metering nozzle), located in the bottom portion of the tundish, that feeds the molten metal to the mold. Antivortexing devices are also used with ladles which supply the tundish or ingot mold at the outflow or collector nozzle. Antivortexing devices in the collector nozzle help prevent spiraling of the metal stream leaving the nozzle, but have little effect in preventing vortexing in the ladle itself. It is therefore desired to provide additional antivortexing means upstream from the collector nozzle so as to further reduce the drawbacks caused by vortexing in the ladle.
For ingot casting, it is known to use nozzles having a central opening in which are disposed flutes to improve the quality of the stream flowing out of the nozzle so as to eliminate the vortexing and spiraling effects previously discussed. The quantity and rate of the flow out of the nozzle is controlled by a metering device, such as a stopper rod or slide gate.
Internal flutes have also been used with nozzles having a circular, triangular, or square central bore. Typically, after a heat is poured, the nozzle is rinsed with oxygen to free it of any unwanted residue. Unfortunately, casting and rinsing contributes to the deterioration of the flutes and limits the operational life of the flutes associated with the nozzles to about three to four heats. Normally, nozzles without fluted arrangements handle between eight to twelve heats before their replacement is necessary. The removal of a fluted inner nozzle from a metering assembly after every three or four heats is impractical and very time-consuming, especially when compared to a non-fluted nozzle that does not require replacement until eight to twelve heats have been poured. It is therefore desired to provide fluted nozzles within metering assemblies which are easy to replace, and at the same time still reduce undesired vortexing.
Casting equipment already in use in existing pouring operations suffers from the drawbacks of vortexing and spiraling. The replacement of existing equipment to correct for undesired vortexing and spiraling would involve a considerable expense and would also consume extensive time.
Accordingly, it is one object of the present invention to provide means easily placed into existing pouring equipment which reduces disadvantageous vortexing and spiraling so as to advantageously and conveniently yield higher quality cast metal.
It is a further object of the present invention to provide a pouring ladle for continuous casting equipment upstream from the tundish which has a fluted nozzle feeding the tundish so as to further inhibit any vortexing or spiraling that would otherwise add impurities or bubbles into molten metal or would otherwise allow for reoxidation of the poured metal, all of which contribute to degrading the quality of the end product being cast.
It is another object of the present invention to provide an antivortexing device that is suitable for a tundish so as to inhibit any vortexing or spiralling that would add impurities or bubbles into a molten metal mold or would otherwise allow for reoxidation of the poured metal.
It is another object of the present invention to provide a nozzle assembly having a fluted portion that not only reduces vortexing and spiraling conditions but also allows for the convenient replacement of the fluted portion.
Other objects and advantages of the present invention will become apparent to those skilled in the art with reference to the attached drawings and description of the invention which hereinafter follows.
SUMMARY OF THE INVENTION
In its broadest aspect, the present invention is directed to antivortexing means for a metal pouring vessel including an outlet orifice having a central opening therein for the passage of molten metal therethrough. The antivortexing means comprises at least one vane extending across the central opening for interacting with molten metal flowing therethrough. The antivortexing means is located at an inlet region of the central opening.
In another aspect, the invention is directed to the combination of a slide gate valve and an antivortexing means. The slide gate valve has an inlet, an outlet, an opening extending between the inlet and the outlet and defining a passage for the flow of molten metal therethrough, and a slide mechanism for selectably closing at least a portion of the opening. The antivortexing means is located in the opening adjacent the inlet and comprises at least one vane extending across the opening for interacting with molten metal flowing therethrough.
In another aspect, the invention is directed to a stopper rod including flutes in combination with an antivortexing means for a metal pouring vessel including an outlet orifice having at least one opening therein for the passage of molten metal therethrough. The stopper rod is configured for selectably closing the opening in the outlet orifice.
In a further embodiment, the invention is directed to a molten metal pouring system comprising:
(1) a first molten metal holding and pouring box with first predetermined dimensions;
(2) a second molten metal holding and pouring box with second predetermined dimensions which are less than said first predetermined dimensions and which is positioned relative to said first molten metal holding and pouring box to receive a flow of molten metal therefrom;
(3) a first means for controlling the outflow of molten metal located at the bottom region of the first molten metal holding and pouring box;
(4) antivortexing means located in an inlet portion of said first means for controlling the outflow of molten metal and in direct contact with the molten metal in said holding and pouring box, said antivortexing means having a central opening and at least one vane for interacting with the molten metal as it flows into the central opening to reduce vortexing; and
(5) a second means for controlling the outflow of molten metal and located at the bottom region of the said second molten metal holding and pouring box, said second means controlling the outflow of molten metal to casting molds.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there is shown in the drawings a form which is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 illustrates the interrelationship of the primary elements of the molten metal pouring system of the present invention.
FIG. 2 is an illustration of the metering nozzle assembly of the present invention.
FIGS. 3, 4 and 4a illustrate one embodiment of the insert which reduces vortexing of the outflow of molten metal from the metering assembly.
FIGS. 5, 6, 7, 7a, 8, 9 and 10 illustrate alternative embodiments of the insert, which reduce vortexing of the outflow of metal o from the metering assembly.
FIG. 11(a-b) is a modified stoper rod including flutes near the base of the stopper rod.
FIG. 12(a-b) illustrates a vortex suppressing insert that incorporates flutes to be used in combination with a stopper rod which reduce vortexing of the outflow of molten metal from the metering assembly.
FIG. 3(a-b) illustrates a modified subentry shroud adapted to engage a stopper rod to selectably close at least a portion of an outlet orifice.
DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein like numerals indicate like elements, there is shown in FIG. 1 a system 10 for use in continuous casting and in FIG. 2 a metering assembly 12. The system 10 and the metering assembly 12 both pertain to the continuous casting of molten metal, and both the system 10 and the metering assembly 12 reduce vortexing and spiraling which normally occur when pouring molten meal into molds and tundishes and which sometimes cause slag to be entrained into the meal being poured, or bubbles or voids to be created in the cast meal. While the antivortexing insert described herein is equally effective in a tundish as in a ladle, the following description will be directed primarily to insallation in a ladle for clarity. The methods for using the antivortexing insert in a tundish and a ladle are the same.
The system 10 pertains primarily to controlling the outflow of the molten meal 14 from each of the metering assemblies 12 so as to provide a non-turbulent, laminar type flow 12A. The system 10 comprises a first molten meal holding and pouring box in the form of pouring ladle 16 and a second molten meal holding and pouring box in the form of tundish 18, both of which contain molten metal 14. As is typical, molten metal 14 has a layer of slag 20 on its upper surface. Each of the first and second holding and pouring boxes 16 and 18 comprise a shell 22, preferably made of high temperature steel, and a lining 24, preferably of a refractory material. Each of the boxes 16 and 18 have predetermined dimensions, with the box 16 having a volume which is substantially greater than that of the box 18.
In molten metal pouring systems, the larger box 16 is generally referred to as a ladle and the smaller box 18 is generally referred to as a tundish, as mentioned above. (The terms ladle and first molten metal holding and pouring box, as well as the terms tundish and molten meal second holding and pouring box, are used herein interchangeably.) The tundish 18 is positioned downstream from the ladle 16 and receives the outflow of molten metal being poured from the ladle 16. The ladle 16 and tundish 18 provide molten metal 14 to be used for the casting of billets, blooms, slabs or strips 26.
The flow rate (Q) of molten metal 14 being poured from either molten metal holding and pouring box 16 or 18 is a function of the height of the molten metal within the respective box (the "ferrostatic head"), the size of the bore or orifice of the nozzle from which the molten metal flows, and the operation of a flow control mechanism, such as a slide gate valve 12 or a stopper rod assembly 28. In addition, since flow is a function of nozzle opening dimensions, the outflow may be left uncontrolled by either a slide gate valve or a stopper rod, and instead controlled by a metering nozzle 30. It should be mentioned here that a stopper rod 28 is typically used only with the tundish 18, and not with ladle 16.
The tundish 18 is positioned directly over the mold or molds to be cast, and may include a plurality of nozzles each located in the bottom region of the tundish 18, and each supplying molten metal to a respective mold, so that a plurality of shapes, such as steel billets, blooms, slabs or strips, are cast. The stopper rod mechanism 28 may be used to control the quantity of the flow of molten metal out of tundish 18, and such a mechanism is well-known in the art.
As further shown in FIG. 1, the second molten metal holding and pouring box 18 is positioned over a mold 26. The outflow of molten metal from the second box 18 is directed into a subentry shroud or subentry nozzle 32 of mold 26. This allows the flow of molten metal to be directed, by gravity, into mold 26. The casting of the mold 26 is accomplished in an integrated manner with the control of the output flow provided by, for example, a stopper rod mechanism 28, a slide gate valve or a metering nozzle, in known manner.
The metering assembly will be further described with reference to FIG. 2. The metering assembly 12 controls the outflow of the molten metal from the box 16. The metering assembly 12 comprises an insert 36 and a well block 52. Well block 52 comprises two nozzle elements, an upper well nozzle 42 and a lower well nozzle 44. Metering assembly 12 further comprises a stationary plate 48 held in place by a stationary plate retainer 50 (also known as a base plate or mounting plate), and a mobile plate 56 and a collector nozzle 46. The insert 36, the nozzle elements 42, 44, 46, and stationary plate 48 are each preferably composed of a refractory material. The insert 36 defines at least one opening 36A. Nozzle elements 42, 44, 46 and stationary plate 48, respectively, have central openings 42A, 44A, 46A and 48A. The insert 36, and the upper well nozzle 42 and the lower well nozzle 44 are situated, at least partially, within the bottom refractory lining 24 of the bottom wall of, preferably, box 16 is supported thereat by means of a pocket block or well block 52 comprising a refractory material. Adjacent the well block 52 is a leveling plate 54.
The stationary plate 48 is positioned between the lower well nozzle 44 and the collector nozzle 46. A movable slide plate 56 supports and is attached to the upper region of the collector nozzle 46. The slide plate 56 cooperates with the stationary plate 48 and forms a typical slide gate control device. The slide gate control device further comprises a slide gate mechanism 58 that is mounted to its associated box 16 by means of a mounting plate 60.
The slide gate mechanism 58 has a carriage 62 which includes a spring mounted mechanism 64 that assists in keeping slide plate 56 in close contact with stationary plate 48. The carriage 62 is laterally moved by an external device (not shown) attached to arm 66. Carriage 62 is moved by an amount or distance 68 shown in FIG. 2. The extremes of movement, related to distance 68, are identified in FIG. 2 as the CLOSED and OPEN positions, as will be well known to those skilled in this art. Normally when the gate is in the OPEN position, without the benefits of the present invention or without some type of insert, vortexing and spiraling would be present in the outflow of molten metal from the metering assembly 12.
An alternative metering assembly comprises a stopper rod assembly 28, an insert 36 and a modified subentry shroud 32. As shown in FIG. 11, stopper rod 28 further comprises an upper section 28A and a lower base or tip section 28B. Base 28B further comprises flutes or vanes 92 arranged around its circumference. Insert 36 defines at least one opening 36A. The modified stopper rod 28 is constructed of conventional material known to those skilled in the art. The stopper rod 28 must be capable of working in a molten metal environment without any degradation of its structural integrity. Stopper rod 28 is affixed to a power source capable of lifting stopper rod 28 vertically to permit molten metal to flow through opening 36A and into subentry shroud 32.
A metering assembly not having the benefits of the present invention may be visualized from FIG. 2 by removing insert 36 from the metering assembly and considering the freed-up space as being the throat of the well block 52. After the removal of insert section 36, the metering assembly will suffer from the drawbacks of vortexing and spiraling. Spiral could be reduced by the use of a collector-nozzle 46 which includes flutes arranged within its central bore, such as a six-sided symmetrical arrangement of half-circles located about the circumference of the central bore. Such solutions are being used successfully as a means for reducing stream spiraling, but not vortexing. Flutes have also been previously tried in the upper and lower well nozzles, but are not practical. Unfortunately, and as described in the "Background" section, the anticipated life of the flutes in the well nozzles or inner nozzles is somewhat limited and their replacement is relatively expensive but, more importantly, they are relatively difficult to replace because they must be first removed from the confines of the well block 52. The present invention eliminates these difficulties by permitting the insert 36 to be simply dropped into place in the throat of well block 52 and by using a standard collector nozzle (such as nozzle 46 of FIG. 2) having a central bore that does not include any flutes. When the insert 36 (having an anticipated life similar to that of the prior art fluted collector nozzle) needs to be replaced, the worn out insert 36 is merely lifted out of the throat of the well block 52 and its replacement is dropped into place in the same throat. Unlike prior art devices, the insert 36 allows the metering nozzle assembly to be restored to its operational readiness with only minor delay.
The insert 36 is further described with reference to FIGS. 3, 4, 4a, 7 and 7a. The insert 36 shown in FIG. 3 is shown in combination with a housing comprising an outer wall having a base 82 and upper edge 84. The insert 36 shown in FIGS. 4 and 7 can be simply dropped into the throat of the well block 52 and may be operatively located to be in direct contact with the molten metal above the horizontal plane of well block 52. The insert 36 shown in FIGS. 4 and 7 includes central opening 36A which runs through the insert 36. Opening 36A is illustrated as round, but could be square, triangular or have any other cross-sectional shape. Insert 36 has one or more vanes or flutes 92 which extend into opening 36A and interact with the flow of molten metal before it reaches the central opening 36A. The interaction of the flutes with the flowing molten metal breaks up the swirling motion and reduces vortexing. If the insert 36 is combined with the housing, the insert 36 is preferably tapered outward as its outer wall extends from its base 82 to its upper edge 84. The inner wall of the insert 36 has a downwardly curved sloped portion 86 that starts at a location 88 near the upper edge 84 of the insert 36, and tapers downward into the central opening 36A. The insert 36 also comprises a flat surface 90 so that insert 36 lies flush with well block 52. However, the tops of the vanes 92 could extend above the top of edge 84, if desired. The insert 36 further comprises a flute 92 that extends vertically throughout the first section of insert 36.
As seen in FIG. 4a, insert 36 can be provided without a housing. Insert 36 without a housing includes a lower section 94 configured to engage the inner wall of well block 52. Lower section 94 of insert 36 is preferably tapered outward from a bottom edge 96 to the mid-section 98. Midsection 98 of insert 36 lies flush with well block 52. Insert 36 illustrated in FIG. 4a may preferably be configured with two or four vanes 92. More then four vanes 92 may be used but with diminishing improvements per additional vane in relation to spiraling or vortexing.
As seen in FIG. 4, the flute 92 interfers with the spiraling direction of the flow of the molten metal before it enters opening 36A. The flute 92 acts as an antivortexing means to reduce and effectively eliminate any vortexing, i.e., whirling or circular motion of the molten metal, which would otherwise create a force to draw or entrain the slag, located on the surface of the molten metal, toward and into the metal stream.
The flute 92 prevents turbulent flow from occurring and provides a non-turbulent, laminar type flow of molten metal. The laminar flow (shown in FIG. 1 as 12A) provided by the present invention results in a substantial reduction in vortexing and spiraling associated with prior art nozzles not having fluted arrangements, and which would otherwise entrain undesired slag, or other foreign inclusions into the mold or tundish and, thereby, cause flaws in the resulting casted product.
It should be appreciated that the antivortexing means of the present invention is in direct contact with the molten metal 14 in ladle 16, and is located at the inlet to the metering assembly, whereas previously known antivortexing devices have been located in the collector nozzle portion of the metering assembly, at the outlet, or in the upper and lower well nozzle inlet.
An alternative metering assembly may employ a modified stopper rod 28 shown in FIG. 11 to also further reduce vortexing from the tundish. A modified stopper rod 28 includes vanes 92 near the tip or base of the stopper rod 28. Modified stopper rod 28 may include two, four, or more vanes spaced equally around circumference of base 28B of stopper rod 28. The preferred configuration provides four vanes 92 around the circumference of base 28B of stopper rod 28.
A further embodiment of this invention would comprise a stopper rod 28 in combination with a vortex suppressor insert 17. Vortex suppressor insert 17 is characterized by having one or more vanes 19 which extend towards opening 36A and interact with the flow of metal before it reaches opening 36A. The interaction of vanes 19 with the flowing molten metal breaks up the swirling action and reduces vortexing.
A further embodiment of this invention would comprise a stopper rod 28 in combination with a modified sub entry shroud 32. Modified subentry shroud 32 is illustrated in FIG. 13. Subentry shroud 32 has been modified to provide vanes 92 configured to engage the molten metal. In order for molten metal to flow from the tundish into the molds, stopper rod 28 must be lifted vertically from its seating engagement with subentry shroud 32.
Traditionally, it was believed by experts in the field that a stopper rod 28 without vanes 92 suppressed the effects of the vortexing in a metal pouring vessel. However, it has been discovered that a significant amount of surface matter (air) is still being vortexed into the outlet nozzle employing a traditional stopper rod system. As a result of the addition of vanes 92 to the stopper rod 28 near its tip or base, as shown in FIG. 11, 100% of the remaining vortex in a molten metal pouring box employing a modified stopper rod 28 is suppressed. The addition of vanes 19 to tundish bottom 17 in the form of a new piece around the stopper rod seat and/or to the top of subentry shroud 32 will also suppresses any vortexing.
Although the use of devices in the form of an insert have been described as acting as the antivortexing means of the present invention, it should be recognized that other devices having forms different than the flutes described may be used in the practice of this invention. For example, triangular, rectangular, ripple or other shaped extensions may be used so long as a portion of the flow of the molten metal is intercepted and the antivortexing effect is accomplished. Other embodiments of the present invention provide for laminar output flow of the molten metal to the mold and may be further described with reference to FIGS. 5-10.
FIGS. 6 and 7 illustrate a modified insert 36 in combination with a housing. Insert 36 comprises a pair of vanes 92 which are disposed at right angles to each other and which have upper portions configured as semi-circles. The semi-circular configuration of the upper portions of vanes 92 provides greater interaction between the vanes 92 and the molten metal than the configuration shown in FIGS. 3 and 4. The modified insert 36 further comprises a outlet 80 (not shown) whose outer wall extends from base 82 to the upper edge 84. The inner wall of the modified insert 36 has a downwardly sloped portion 86 (not visible in FIG. 7 but visible in the analogous structure in FIG. 4) that starts at location 88 near the upper edge 84. FIG. 7a illustrates the modified insert 36 without a housing. The modified insert 36 without a housing may preferably be configured with two, four, or more vanes which have upper portions configured as semi-circles.
The modified insert 36 further provides a flat surface 90 to permit the modified insert 36 to rest flush with well block 52. With respect to insert 36 shown in FIG. 7a, mid-section 98 lies flush with well block 52. While vanes 92 are shown extending beyond the outer edge 84 in FIGS. 6 and 7, the modified insert 36 could be further modified to terminate one or more of the vanes 92 at the outer edge, as shown in FIG. 8, and still obtain an acceptable reduction in vortexing. Likewise, insert 36, shown in FIGS. 3 and 4 may be modified in a similar manner, as shown in FIG. 9.
A further embodiment is shown in FIG. 10. The insert 36 shown in FIG. 10 comprises a combination of a nozzle insert including a plurality of vanes 92 extending into central opening 36A, and one vane 92 that extends entirely across the central opening 36A to intercept a portion of the molten metal flowing therethrough. The vanes 92 comprise an upper portion that may be configured as rectangular, triangular, ripple, or semicircular so long as a portion of the flow of molten metal is intercepted and the antivortexing effect is accomplished.
As already mentioned, FIG. 1 illustrates a system 10 similar to prior art molten metal pouring systems. However, unlike prior art molten metal casting systems, system 10 also has a fluted nozzle in the path of the outflow of molten metal from the ladle 16. The placement of the fluted nozzle in the ladle 16 decreases the amount of metal that would otherwise be treated as scrap and, thereby, decreases the attendant cost involved with reprocessing scrap metal.
More particularly, a typical pouring process, applicable to either arrangement having a fluted nozzle in both the ladle 16 and tundish 18 or with the fluted nozzle in only the tundish 18, involves somewhere between 250 to 400 tons of steel. Typically, when pouring 250 to 400 tons of steel in a system having the fluted nozzle in only tundish 18, the slag 20 that is present on the surface of the molten metal 20 of ladle 16 begins to be vortexed into the outflow of molten metal from the ladle 16 to the tundish 18. When this occurs, the outflow of molten metal from the ladle 16 is stopped. Typically, 2 to 4% of the molten metal, or 10,000 to 32,000 pounds, remains in ladle 16. This amount of metal is removed and remelted. The remelting of scrap metal costs about $100.00/ton and, therefore, the cost of returning and heating 10,000 to 32,000 pounds of metal results in a remelting cost of between $500.00 to $1,600.00, respectively. The present invention, by providing the means for reducing the vortexing condition that might otherwise exist in the ladle 16, reduces the amount of scrap metal from the range of between 10,000 to 32,000 pounds to an amount of about 1,000 pounds.
Reducing the scrap metal from 10,000 pounds to 1,000 pounds per heat yields a savings of approximately $450.00 per heat, which corresponds to the unnecessary cost of reheating 9,000 (10,000-1,000) pounds. This value increases to about $1,550.00 per heat when 31,000 (32,000-1,000) pounds of scrap metal are eliminated from being reheated.
It should now be appreciated that the practice of the present invention by providing a fluted nozzle in the ladle of the molten metal pouring equipment yields substantial cost benefits, while still resulting in a cast product that is substantially free of flaws.
Moreover, the present invention provides a solution to a problem that has plagued metal casting operations. This solution is conveniently implemented and its benefits are substantial.
Furthermore, it should be appreciated that the present invention provide a single piece, more particularly an insert, that is easily installed into an existing metering assembly, so as to conveniently retrofit existing ladles to provide a molten metal pouring system having the benefits of the present invention.
Although the previously described molten metal pouring system comprises a fluted nozzle in each of the ladle 16 and the tundish 18, it should be recognized that the system 10 need only have the fluted nozzle arrangement in the ladle 16 to yield the benefits of the present invention. Furthermore, for such arrangements, the tundish 18 need only have a nozzle to control or direct the outflow of molten metal and need not have an on-off control device such as the slide-gate assembly 58 of FIG. 2.
Further, although the metering assembly 12 of FIG. 2 has been described as comprising the insert 36 and the nozzle sections 42, 44, 46 and 48, it should be realized that the nozzle sections 42 and 44 may be integrated into one nozzle section.
The present invention is best suited for continuous casting of metal products such as billets, blooms, slabs and strips. However, the invention is also useful in uphill teeming or top casting of ingots. Moreover, the invention can be used in other metal casting operations.
The present invention may be embodied in other specific forms without departing from the spirit for essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing, specification, as indicating the scope of the invention. | A system and a metering assembly are both disclosed, and both relate to reducing the vortexing which can occur during the outflow of molten metal from a holding reservoir to a mold during casting operations. The system includes a first molten metal holding and pouring box with first predetermined dimensions, a second molten metal holding and pouring box with second predetermined dimensions which are less than said first predetermined dimensions and which is positioned relative to said first molten metal holding and pouring box to receive a flow of molten metal therefrom, a first flow control device for controlling the outflow of molten metal located at the bottom region of the first molten metal holding and pouring box, an antivortexing insert located in an inlet portion of said first flow control device for controlling the outflow of molten metal and in direct contact with the molten metal in said holding and pouring box. The antivortexing insert has at least one opening and at least one vane for interacting with the molten metal as it flows into the inlet portion of the first flow control device to reduce vortexing. In its broadest aspect, the present invention is directed to antivortexing insert for a metal pouring vessel including an outlet orifice having a central opening therein for the passage of molten metal therethrough. The antivortexing insert comprises at least one vane extending across the central opening for interacting with molten metal flowing therethrough. The antivortexing insert is located at an inlet region of the central opening. | 1 |
TECHNICAL FIELD
[0001] Embodiments pertain to camera-vision devices, systems, and methods, used in collaboration whiteboards, for pre-formatted, reusable, annotatable, movable menus and forms.
BACKGROUND
[0002] Typically, a whiteboard collaboration environment uses a camera, image capture, and/or optical character recognition to tag specific items that are under discussion for action items or for future reference, to select drawing controls, and/or to enter data into a collaboration system.
SUMMARY
[0003] Embodiments provide the functionality for inputting information into a camera-vision based collaboration environment. Embodiments pertain to systems and devices for, and methods of, an image-based computer processor configured to capture surface indicia, determine an image reference associated with it, extract a set of one or more markings based on the image reference, and invoke a rule of execution based on the rule of interpretation associated with the image reference.
[0004] Device embodiments may comprise a processor; an addressable memory, the memory comprising a set of one or more image references, and where the set of image references comprises a rule of interpretation and a rule of execution; and where the processor may be configured to: (a) compare captured surface indicia of a sheet with the set of at least one image reference; (b) determine the image reference associated with the surface indicia based on the comparison of the surface indicia and the set of at least one image reference; (c) extract a marking by differencing the surface indicia and the image reference; (d) interpret the extracted marking based on the rule of interpretation associated with the image reference; and (e) invoke the rule of execution based on the rule of interpretation. Some embodiments may be further configured to receive data from at least one of a camera, video capturing device, digital video recorder, scanning camera, webcam, and motion capture device. Some embodiments may compare the surface indicia with at least one image reference via a visual process and by using a detection method further comprising at least one of edge detection, geometric shape detection, and bar code detection. The extraction of the markings may be implemented via at least one of: visual differencing, pattern recognition, optical mark recognition, and optical character recognition. In an embodiment the processor may be further configured to determine a marking on at least a portion of the surface indicia, indicative of immediate invocation of the rule of execution based on the rule of interpretation.
[0005] Method embodiments may comprise: (a) capturing a surface indicia of a sheet; (b) comparing the surface indicia with a set of at least one image reference, where the image reference comprises a set of rules, and where each set of rules comprises a set of at least one rule of interpretation and a set of at least one rule of execution; (c) determining the image reference associated with the surface indicia based on the comparison of the captured surface indicia and the set of at least one image reference; (d) extracting a marking by differencing the surface indicia and the image reference; (e) interpreting the extracted marking based on the set of rules according to the image reference; and (f) invoking the rule of execution based on the rule of interpretation.
[0006] System embodiments may comprise: (a) a set of one or more predefined indicia; (b) a surface configured to receive markings. The system also comprising an image capture device, configured to capture an image of a portion of the sheet element. The system further comprising (a) an image capture device configured to capture surface indicia of a sheet and (b) an image-based computer processing device comprising: a processor and addressable memory, the memory comprising a set of one or more image references, where each member of the set of image references comprises a rule of interpretation and a rule of execution; and the processor may be configured to: (1) compare the surface indicia with the set of at least one image reference; (2) determine the image reference associated with the surface indicia based on the comparison of the surface indicia and the set of at least one image reference; (3) extract a marking by differencing the surface indicia and the image reference; (4) interpret the extracted marking based on the rule of interpretation associated with the image reference; and (5) invoke the rule of execution based on the rule of interpretation. Some embodiments of the sheet element may further comprise flexible, electro-static, and/or nontranslucent material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, and in which:
[0008] FIG. 1 is a functional block diagram depicting an exemplary image-based collaboration system environment;
[0009] FIG. 2 is a functional block diagram depicting an exemplary image-based collaboration system environment that also optionally includes a collaboration server, a display at a remote site, and one or more offsite nodes and/or data storage;
[0010] FIG. 3 is a functional block diagram depicting an exemplary image-based collaboration system environment, where the whiteboard contains a plurality of sheets;
[0011] FIG. 4 is a functional block diagram depicting an exemplary image-based collaboration system environment, where the system has identified the input form or menu locations on the whiteboard as hot-zones;
[0012] FIG. 5 is a functional block diagram depicting an exemplary image-based collaboration system environment, where one of the sheets has been either relocated or removed and replaced with a new one;
[0013] FIG. 6 further shows the embodiment as in FIG. 5 where a new hot-zone is identified and established for monitoring;
[0014] FIG. 7 is a flowchart depicting an exemplary functional block diagram of an image-based collaboration system environment;
[0015] FIG. 8 depicts an exemplary embodiment of a surface indicia of a pre-printed sheet that shows the example input forms and menus designated as hot-zones;
[0016] FIG. 9 depicts an exemplary embodiment of a surface indicia of a pre-printed sheet;
[0017] FIG. 10 depicts an exemplary embodiment of a surface indicia of a pre-printed sheet;
[0018] FIG. 11 depicts an exemplary embodiment of a surface indicia of a pre-printed sheet with markings;
[0019] FIG. 12 depicts an exemplary embodiment of a surface indicia with the extracted markings on the sheet;
[0020] FIG. 13 depicts an exemplary embodiment of a surface indicia of a pre-printed sheet with markings; and
[0021] FIG. 14 depicts an exemplary embodiment of a surface indicia with the extracted markings on the sheet.
DETAILED DESCRIPTION
[0022] FIG. 1 is a functional block diagram depicting an exemplary image-based collaboration system environment 100 . A system embodiment is depicted in FIG. 1 as comprising a whiteboard 110 that contains a set of one or more sheets 112 , an image capture device 130 , and an image-based computer processing device 140 . Embodiments of the image-based collaboration system 100 may be executed in real time or near real time, and the information may be at least one of received, read and captured from the sheet 112 or a portion thereof. An image capture device 130 is depicted as capturing an image of a portion of the collaboration whiteboard 110 , e.g., a sheet 112 containing a set of one or more predefined indicia. The image capture device 130 may be at least one of a camera, video capturing device, digital video recorder, scanning camera, webcam, and motion capture device. An image-based computer processing device 140 may be configured to compare the captured surface indicia with a set of at least one image references and determine the image reference associated with the surface indicia. By comparing the surface indicia with the set of at least one image reference, and then extracting the difference between them, a set of markings may be identified. Once a marking has been extracted from the surface indicia it may be interpreted based on the image reference. The image reference may additionally contain a rule of execution or a set of instructions associated with the interpretation.
[0023] FIG. 2 is a functional block diagram depicting an exemplary image-based collaboration system environment 200 that comprises a whiteboard 210 , an image capture device 230 , an image-based computer processing device 240 , a display at a remote site 250 , e.g., LCD display, a collaboration server 260 , and one or more offsite nodes and/or data storage 270 , e.g., collaboration cloud, that may be used for maintaining an associated image reference. In this embodiment the whiteboard 210 may be monitored by an image capture device 230 , e.g., camera-vision system, that is collaborating with an image-based computer processing device 240 , e.g., collaboration computer. The image references may be stored in any one of the collaboration computer 240 , collaboration server 260 , collaboration cloud 270 , or in some combination. Optionally, the resulting output may be displayed on a remote site display 250 .
[0024] FIG. 3 is a functional block diagram depicting an exemplary image-based collaboration system environment 300 that comprises a whiteboard 310 that contains a set of one or more sheets 312 , 314 , an image capture device 330 , an image-based computer processing device 340 , a display at a remote site 350 , e.g., LCD display, a collaboration server 360 , and one or more offsite nodes and/or data storage 370 , e.g., collaboration cloud that may be used for maintaining an associated image reference. In this exemplary embodiment, the whiteboard 310 is depicted as being monitored by an image capture device 330 that may be controlled by the image-based computer processing device 340 , e.g., a collaboration computer. The image references may be stored in any one of the collaboration computer 340 , a collaboration server 360 , a collaboration cloud 370 , i.e., distributed network storage, or in some combination thereof. Optionally, the resulting output may be displayed on a remote site display 350 . The plurality of sheets 312 , 314 may contain a set of one or more predefined indicia and a surface configured to receive markings. A user may dispose one or more sheets within or about the collaboration environment that, in this example, includes a whiteboard 310 . The image capture device 330 may detect changes to the disposition and/or orientation of one or more sheets 312 , 314 on the whiteboard 310 , and capture the surface indicia of the sheet. The predefined indicia may be identified by comparing the surface indicia, e.g., a unique identifying number or symbol with a set of at least one image reference.
[0025] FIG. 4 is a functional block diagram depicting an exemplary image-based collaboration system environment 400 that comprises a whiteboard 410 that contains a set of one or more sheets 412 , 414 , an image capture device 430 , an image-based computer processing device 440 , a display at a remote site 450 , e.g., LCD display, a collaboration server 460 , and one or more offsite nodes and/or data storage 470 , e.g., collaboration cloud that may be used for maintaining an associated image reference. In an embodiment the whiteboard 410 is being monitored by an image capture device 430 that may be controlled by the image-based computer processing device 440 , e.g., collaboration computer. The image references may be stored in any one of the collaboration computer 440 , a collaboration server 460 , a collaboration cloud 470 , or in some combination thereof. The whiteboard 410 may contain a plurality of sheets 412 , 414 , e.g. two input forms or menus, containing a set of one or more predefined indicia and a surface configured to receive markings. The image capture device 430 may detect the changes to the whiteboard 410 and in turn capture the surface indicia of the sheet. The predefined indicia may be identified by comparing the surface indicia, e.g., a unique identifying number or symbol with a set of at least one image reference. The image reference 482 associated with sheet 412 may be determined and the interpretation and/or execution rules are optionally loaded into the memory of the collaboration computer 440 . In the embodiment, the interpretation and/or execution rules 484 associated with sheet 414 may be loaded into the memory of the collaboration cloud 470 . The system is depicted as having identified the input form or menu locations on the whiteboard as hot-zones. It may monitor those hot-zones for any activity, i.e., changes in markings on the identified sheets. Optionally, the system may determine if a de-skew and/or rotation factor may be required to enhance the interpretation of the surface indicia, e.g., the input form or menu, by the system. If so, the system may attach de-skew and/or rotation information to that hot-zone so that all future image capturing of that section may be properly de-skewed and/or rotated before analysis of the content.
[0026] FIG. 5 is a functional block diagram depicting an exemplary image-based collaboration system environment 500 as in FIG. 4 , that comprises a whiteboard 510 that contains a set of one or more sheets 512 , 516 , an image capture device 530 , an image-based computer processing device 540 , a display at a remote site 550 , e.g., LCD display, a collaboration server 560 , and one or more offsite nodes and/or data storage 570 , e.g., collaboration cloud that may be used for maintaining an associated image reference. In FIG. 5 , the sheet 414 on the bottom right corner of FIG. 4 is depicted as being removed and replaced with a new sheet 516 on the bottom left corner. The image reference 582 associated with sheet 512 may be determined and the interpretation and/or execution rules are optionally loaded into the memory of the collaboration computer 540 . The removed sheet 414 and the spatial location of that collaboration environment is given a provisional deletion status. The image reference and the interpretation and/or execution rules 484 associated with the removed sheet 414 may be provisionally deleted 590 from the current workspace. Optionally, the interpretation and/or execution rules 484 may be retained in cache. The image capture device 530 may detect the changes to the whiteboard 510 and in turn capture the surface indicia of the new sheet 516 . The predefined indicia may be identified by comparing the surface indicia, e.g., a unique identifying number or symbol with a set of at least one image reference. The image reference 586 associated with the new sheet 516 may be determined and the interpretation and/or execution rules are optionally loaded into the memory of the collaboration server 560 . In this example, a sheet may also be relocated from one area of the whiteboard 510 to another and the image capture device 530 may then detect the changes to the whiteboard 510 and in turn capture the surface indicia of the relocated sheet.
[0027] FIG. 6 is a functional block diagram depicting an exemplary image-based collaboration system environment 600 , that comprises a whiteboard 610 that contains a set of one or more sheets 612 , 616 , an image capture device 630 , an image-based computer processing device 640 , a display at a remote site 650 , e.g., LCD display, a collaboration server 660 , and one or more offsite nodes and/or data storage 670 , e.g., collaboration cloud that may be used for maintaining an associated image reference. New surface indicia 616 may then be placed on the whiteboard and further identified. FIG. 6 further shows the embodiment of FIG. 5 where a new hot-zone may be identified and established for monitoring. The image reference 682 associated with sheet 612 and the interpretation and/or execution rules, as determined previously, are optionally loaded into the memory of the collaboration computer 640 . The system is depicted as having identified the input form or menu locations on the whiteboard as hot-zones. It may now monitor those hot-zones for any activity, i.e., changes in markings on the identified sheets 612 and 616 . The interpretation and/or execution rules 696 for sheet 616 are determined and the extracted marking may be interpreted based on the rule of interpretation and the associated rule of execution is optionally invoked.
[0028] FIG. 7 is a flowchart depicting an exemplary functional block diagram of an image-based collaboration system environment 700 . The system may capture a surface indicia of a sheet by way of an image capture device (step 710 ). The surface indicia may then be compared with a set of at least one image reference (step 720 ). The image reference associated with the surface indicia may be determined based on the comparison of the surface indicia and the set of at least one image reference (step 730 ). In the next step, a marking may be extracted from the surface indicia based on the comparison of the surface indicia and the set of at least one image reference (step 740 ). The extracted marking may then be interpreted based on the rule of interpretation associated with the image reference (step 750 ). The rule of execution may then be invoked based on the rule of interpretation (step 760 ).
[0029] In an embodiment the sheet element may be flexible vinyl, Mylar®, poly sheets, or other similar materials. The physical attributes of the sheet may be nontranslucent and may include a set of light colors, e.g., white. Light colors would allow the computer vision system to locate the menu on the whiteboard easier, e.g., by comparing chromatic differences. The sheet may optionally have a natural electro-static capability so that it may be attached and removed from the surface of the whiteboard using just the electro-static charge. The surface may be compatible with the use of various style markers and erasers, for example, dry-erase, glossy, water-proof, and washable. The sheet may optionally be made out of a thick material to resist bubbling and wrinkling.
[0030] FIG. 8 depicts an exemplary embodiment of a surface indicia of a pre-printed sheet 800 . The sheet 800 may have a unique identifying symbol, e.g., any one of, name 810 , identification number 815 , barcode 820 , or in some combination printed on the sheet. The portion of the surface indicia containing the aforementioned objects may be readable by the computer-vision system, and used to identify the image reference associated with the sheet. Optionally, highlighting color(s) may also be used in conjunction with the above methods to add to the ability of the system to locate, identify and validate the sheets. In this embodiment, the sheet may have a combination of identifying marks 810 , 815 , 820 , boundary markings 840 , and/or heavy border lines 830 to allow the computer-vision system to easily determine the orientation and boundaries of the image reference. Thus the system may de-skew and/or rotate to normalize the view of the surface indicia as needed based on these objects. Hot-zones 860 within the sheet 800 may be identified where markings may be received and captured from the surface indicia of the sheet 800 .
[0031] FIG. 9 depicts another embodiment of a surface indicia of a pre-printed sheet 900 . The sheet 900 may have a unique identifying symbol, e.g., one of at least a set of name 910 , identification number 915 , barcode 920 , or in some combination printed on it. The portion of the surface indicia containing the aforementioned objects may be readable by the computer-vision system, and used to identify the image reference associated with the sheet to the system. In this embodiment, the sheet may have a combination of identifying marks 910 , 915 , 920 , and/or boundary markings 940 and/or heavy border lines 930 to allow the computer-vision system to determine the orientation and boundaries of the image reference. The hot-zones 960 on the surface indicia of the sheet 900 may be marked at any time.
[0032] In an embodiment, the sheet may have a “do it now” object 950 , where the input forms or menus may require complex or multiple user changes before the inputs or changes are ready to be processed. These input forms or menus may have a “do it now” object 950 as an indicator to the system signifying that the data is ready for processing. If the user has marked the “do it now” object 950 , the image based computer processing device identifies the markings and determines the associated reference. In certain embodiments, once the processing of the user inputs are completed, the system may then provide feedback to the user that the data has been processed, e.g., an audio beep. In some “do it now” embodiments, hot-zones 960 may be identified and markings may be received and captured from the surface indicia of the sheet 900 . In an embodiment, the “do it now” action may be implemented so that upon receiving the feedback from the system, e.g., an audio beep that indicates or announces that the data has been processed, the user resets the “do it now” button by erasing the mark from the input forms or menu or by removing the sheet and replacing it or some other reset functionality. The system may ignore any further changes to the hot-zone 960 until the “do it now button” is once again set by the user. In this example, the changes may be processed at this point. In other embodiments, the “do it now” action is depicted such that upon receiving the feedback from the system, e.g., an audio beep that indicate or announces that the data has been processed and thereafter, the user may take no further action to reset the “do it now” functionality. The system may ignore any further changes to the hot-zone 960 until the “do it now” button is first cleared, and then reset by the user. At that point the changes may be processed similarly to the first time the “do it now” object 950 was marked.
[0033] While each surface indicia may be designated a hot-zone 960 and monitored for changes, the image references themselves may define actual areas within the sheet 900 . Where changes are made to the content, it may initiate some action or activity, or indicate data to be entered into the system. For example, in FIG. 8 and FIG. 9 , the sample sheets are designated as having at least one “hot-zone” 860 , 960 . Within each captured image, which may be a portion of the collaboration whiteboard, specific areas of the sheet are monitored for changes which may trigger the action or activity, or indicate data to be entered into the system.
[0034] FIG. 10 depicts an exemplary embodiment of a surface indicia of a pre-printed sheet 1000 , as in FIG. 8 . This exemplary sheet contains menu options with the specialized purpose of assisting in creating a drawing, graph, chart, etc. As before, the sheet 1000 may have a unique identifying symbol printed on it, e.g., one of at least a set of name 1010 , identification number 1015 , barcode 1020 , or in some combination, printed on the sheet. The portion of the surface indicia containing the aforementioned objects may be readable by the computer-vision system, and used to identify the image reference associated with the sheet. Optionally, one or more highlighting colors may also be used in conjunction with the above methods, in order to enhance the ability of the system to locate, identify and validate them. In this embodiment, the sheet may have a combination of identifying marks 1010 , 1015 , 1020 , and/or boundary markings 1040 and/or heavy border lines 1030 to allow the computer-vision system to easily determine the orientation and boundaries of the image reference. Thus the system may de-skew and/or rotate to normalize the view of the surface indicia, as needed based on these objects. Markings 1070 received from the hot-zone area may be captured from the surface indicia of the sheet and extracted.
[0035] FIG. 11 depicts an exemplary embodiment of a surface indicia of a pre-printed sheet 1100 with markings. This exemplary sheet 1100 may also have one of at least a set of unique identifying symbols, e.g., one of at least a set of name 1110 , identification number 1115 , barcode 1120 , or in some combination printed on it. The portion of the surface indicia containing the aforementioned objects may be readable by the computer-vision system that identifies the image reference associated with the sheet. The sheet may have a combination of identifying marks 1110 , 1115 , 1120 , and/or boundary markings 1140 and/or heavy border lines 1130 to allow the computer-vision system to easily determine the orientation and boundaries of the image reference. Optionally, the sheet may have a “do it now” object 1150 where some input forms or menus may require complex or multiple user changes before it may be ready to be processed. This particular exemplary sheet contains menu options with the specialized purpose of assisting in creating and entering user defined meta-data or tags into the system. Some embodiments may apply optical character recognition (OCR) processing. In some embodiments, the system may include handwritten-text-to-OCR processing to convert the received meta-data to binary text. In another embodiment, the system may detect the image boundaries around each received meta-data entry, and converts the handwriting into a small bitmap. That bitmap may then be used as a tag that is associated with the current set of at least one of action, activity, time-stamp, and document.
[0036] FIG. 12 depicts an exemplary embodiment of a surface indicia with the extracted markings on the sheet 1200 . This exemplary sheet 1200 may also have one of at least a set of unique identifying symbols, e.g., one of at least a set of name 1210 , identification number 1215 , barcode 1220 , or in some combination printed on it. The portion of the surface indicia containing the aforementioned objects may be readable by the computer-vision system that identifies the image reference associated with the sheet. The sheet may have a combination of identifying marks 1210 , 1215 , 1220 , and/or boundary markings 1240 and/or heavy border lines 1230 to allow the computer-vision system to easily determine the orientation and boundaries of the image reference. This exemplary sheet contains the interpreted markings from the sheet 1100 in FIG. 11 . In this embodiment, the “do it now” object 1250 has been marked signifying that the markings have been interpreted and the system is ready to process the markings once again. This particular exemplary sheet 1200 contains the menu options with the text interpreted by OCR processing and converted into binary text.
[0037] FIG. 13 depicts an exemplary embodiment of a surface indicia of a pre-printed sheet 1300 with markings. This exemplary sheet 1300 may have a unique identifying symbol, e.g., any one of, name 1310 , identification number 1315 , barcode 1320 , or in some combination printed on the sheet. The portion of the surface indicia containing the aforementioned objects may be readable by the computer-vision system, and used to identify the image reference associated with the sheet. The sheet may have a combination of identifying marks 1310 , 1315 , 1320 , and/or boundary markings 1340 and/or heavy border lines 1330 to allow the computer-vision system to easily determine the orientation and boundaries of the image reference. This particular exemplary sheet contains menu options with the specialized purpose of assisting in creating and entering user defined meta-data or tags into the system. In an embodiment, the system may convert handwritten text to OCR with special software to convert the received meta-data to binary text. In this embodiment the system may receive data, e.g., color names to be identified and applied to electronic ink.
[0038] FIG. 14 depicts an exemplary embodiment of a surface indicia with the extracted markings on the sheet 1400 . This exemplary sheet 1400 may have a unique identifying symbol, e.g., any one of, name 1410 , identification number 1415 , barcode 1420 , or in some combination printed on the sheet. In this embodiment, the sheet may have a combination of identifying marks 1410 , 1415 , 1420 , and/or boundary markings 1440 and/or heavy border lines 1430 to allow the computer-vision system to easily determine the orientation and boundaries of the image reference. This particular exemplary sheet contains the menu options along with the color names interpreted by OCR software and converted into binary text.
[0039] It is contemplated that various combinations and/or sub-combinations of the specific features and aspects of the above embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments may be combined with or substituted for one another in order to form varying modes of the disclosed invention. Further it is intended that the scope of the present invention is herein disclosed by way of examples and should not be limited by the particular disclosed embodiments described above. | Systems and devices for, and methods of, image-based processing where a device embodiment comprises: (a) a processor; (b) an addressable memory, the memory comprising a set one or more image references, and where the set of image references comprises a rule of interpretation and a rule of execution; and the processor is configured to: (1) compare captured surface indicia of a sheet with the set of at least one image reference; (2) determine the image reference associated with the surface indicia based on the comparison of the surface indicia and the set of at least one image reference; (3) extract a marking by differencing the surface indicia and the image reference; (4) interpret the extracted marking based on the rule of interpretation associated with the image reference; and (5) invoke the rule of execution based on the rule of interpretation. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
The present application claims the benefit of U.S. provisional application Ser. No. 61/046,997, filed Apr. 22, 2008, which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates generally to hinges and, more particularly, to hinges used on container doors and the like.
BACKGROUND OF THE INVENTION
Access doors for containers, such as shipping containers, semitrailers, and the like, are typically hinged at one side and secured via a bar lock. The bar lock is typically pivotally mounted opposite the door hinges and is positionable between an open or unlocked position, and a closed or locked position. In the locked position, the bar lock is typically held in position by a shackle, a seal, a padlock, or the like. However, the hinges to which the bar lock is pivotally mounted may have fasteners, such as screws or bolts, that are readily accessible and/or removable, such that the bar lock may be defeated by removing the hinges rather than tampering with the shackle, seal, or padlock.
SUMMARY OF THE INVENTION
The present invention provides an anti-tamper member or plate that is fixedly attached to a hinge, such as the hinge of a bar lock system, in order to prevent access to the fasteners of the hinge when the bar lock is in a closed or locked position. The anti-tamper member substantially covers the fasteners of the hinge in order to discourage or prevent access to the hinge fasteners, thus improving the security of the bar lock.
According to one form of the present invention, the tamper resistant hinge includes a hinge plate, at least one fastener, and an anti-tamper member. The fasteners couple the hinge plate to a mounting surface, such as a door or a wall. The anti-tamper member substantially covers and protects the fasteners in order to inhibit access to the fasteners, thereby limiting or substantially preventing removal of the fasteners and the hinge.
According to another form of the present invention, a tamper resistant hinge, such as for a bar lock assembly on a shipping container or trailer, includes a hinge plate, at least one fastener, a hinge pin, a pivot arm, and an anti-tamper member. The hinge plate defines or forms a passageway for receiving the hinge pin, to which the pivot arm is pivotally coupled. The fasteners, which may be screws, bolts, rivets, or the like, couple the hinge plate to a mounting surface such as a door, a panel, or a wall. The pivot arm defines a passageway for receiving the hinge pin and is pivotally coupled to the hinge plate via the hinge pin so that the pivot arm can pivot between an open position and a closed position. The anti-tamper member is fixed to the pivot arm so that the anti-tamper member substantially covers the fasteners when the pivot arm is in the closed position. The anti-tamper plate exposes the fasteners when the pivot arm is moved to the open position.
In one aspect, the anti-tamper member is a substantially rectangular plate, which may have rounded corners or ends. Optionally, the anti-tamper member may have opposite end portions located at opposite ends of a planar main body portion, the opposite end portions being angled with respect to the main body portion. The angled end portions closely cover the fasteners when the pivot arm is moved to the closed position to prevent prying of the anti-tamper member and to further reduce access to the fasteners.
Therefore, the present invention provides a device that limits or prevents access to the fasteners of a hinge in order to prevent or resist tampering with the fasteners and removal of the hinge. Thus, a locked door or a locked bar lock assembly may be provided with additional security by protecting the hinges from tampering or removal.
These and other objects, advantages, purposes, and features of the present invention will become apparent upon review of the following description in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation of a bar lock system including a pair of tamper resistant hinges in accordance with the present invention;
FIG. 2 is a side elevation of an anti-tamper member;
FIG. 3 is an end sectional view of a hinge assembly, taken along the section designated III in FIG. 1 ;
FIG. 4 is a top perspective view of a hinge assembly in accordance with the present invention;
FIG. 5 is a rear view of the hinge assembly of FIG. 4 , in an open position; and
FIG. 6 is a front view of the hinge assembly of FIG. 4 , in a closed position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and the illustrative embodiments depicted therein, a tamper resistant system 10 includes a bar lock assembly 11 and a pair of tamper resistant hinge assemblies 12 for securing an access door, such as a trailer or container door or the like. As will be more fully described below, each hinge assembly 12 substantially limits or prevents access to fasteners that hold bar lock assembly 11 to the access door or other mounting surface.
Hinge assembly 12 includes a hinge plate 14 , a pivot member 16 , and an anti-tamper member 18 (FIGS. 1 and 3 - 6 ). Hinge assemblies 12 are coupled together by a lock bar 20 that spans between hinge assemblies 12 , which are connected to a mounting surface such as a door 22 . Pivot member 16 is pivotally connected to hinge assembly 12 so that lock bar 20 may be moved or pivoted relative to hinge plate 14 and the mounting surface 22 .
Hinge plate 14 includes a generally planar portion 14 a that is positioned at or near door 22 ( FIGS. 1 and 3 ). Planar portion 14 a includes a pair of holes or passageways 24 ( FIG. 5 ) for receiving fasteners 26 therethrough ( FIG. 3 ). A pair of tangs 14 b project from planar portion 14 a of hinge plate 14 and are curved to form substantially circular passageways for receiving a hinge pin 28 . Hinge plate 14 is mounted to mounting surface 22 via fasteners 26 . Fasteners 26 may be threaded screws, bolts, rivets, or the like, and may be fastened to mounting surface 22 with a receiving member 34 , such as a threaded nut.
Pivot member 16 includes a curved lock bar engaging portion 16 a , a substantially round or circular hinge pin engaging portion 16 b , and a substantially flat planar portion 16 c located between and connecting the bar engaging portion 16 a and the hinge pin engaging portion 16 b . Bar engaging portion 16 a has a radius of curvature substantially conforming to that of lock bar 20 , and may be fixed to the lock bar 20 , such as by welding or with fasteners. Hinge pin engaging portion 16 b is positioned between hinge plate tangs 14 b so that the passageway defined by hinge pin engaging portion 16 b is aligned and substantially coaxial with the passageways defined by tangs 14 b . Optionally, lock bar 20 may be rotatably mounted to pivot member 16 , as may be desirable in certain applications, without departing from the spirit and scope of the present invention.
Hinge pin 28 is installed in passageways of hinge plate tangs 14 b and hinge pin engaging portion 16 b of pivot member 16 so that pivot member 16 is pivotally mounted or coupled to hinge plate 14 . As shown in FIGS. 4 and 5 , hinge plate tangs 14 b may be crimped at their outer portions to preclude or substantially prevent the unauthorized removal of hinge pin 28 . Bushings 30 ( FIGS. 5 and 6 ) may be positioned on either side of hinge pin engaging portion 16 b and around hinge pin 28 to prevent undue wear, binding, noise, and unauthorized access to hinge pin 28 through gaps between hinge pin engaging portion 16 b and hinge plate tangs 14 b . When pivot member 16 is at a closed position ( FIGS. 3 , 4 , and 6 ), planar portion 16 c is adjacent and substantially parallel to hinge plate planar portion 14 a . When pivot member 16 is moved to an open position ( FIG. 5 ), bar engaging portion 16 a and planar portion 16 c extend outwardly away from hinge plate tangs 14 b and generally away from planar portion 14 a of hinge plate 14 .
Anti-tamper member 18 is coupled to planar portion 16 c of pivot member 16 and pivots with pivot member 16 relative to hinge plate 14 . Anti-tamper member 18 has a generally planar main body portion 18 a and opposite end portions 18 b , 18 c extending outwardly from main body portion 18 a ( FIG. 2 ). Anti-tamper member 18 is coupled to pivot member 16 at main body portion 18 a , which may be welded or fastened to planar portion 16 c of pivot member 16 . End portions 18 b , 18 c of anti-tamper member 18 thus extend outwardly beyond planar portion 16 c of pivot member 16 and substantially cover and guard fasteners 26 and portions of hinge plate planar portion 14 a when pivot member 16 is in the closed position ( FIGS. 4 and 6 ). When pivot member 16 is in the open position ( FIG. 5 ), anti-tamper member 18 is positioned away from hinge plate 14 , thus permitting access to hinge plate 14 and fasteners 26 .
Optionally, anti-tamper member end portions 18 b , 18 c are angled relative to main body portion 18 a to reduce the size of any gap that may exist between anti-tamper member 18 and hinge plate planar portion 14 a when pivot member 16 is in the closed position ( FIG. 4 ). For example, anti-tamper member end portions 18 b , 18 c may be angled at about fifteen degrees in order to reduce access to fasteners 26 . Thus, anti-tamper member 18 limits or substantially precludes the use of a pry bar or other tool to access fasteners 26 when pivot member 16 is in the closed position. Anti-tamper member 18 is generally rectangular in shape, and may have rounded corners and/or rounded ends to improve the aesthetics and safety of hinge assembly 12 . Optionally, anti-tamper member 18 may be incorporated into pivot member 16 or unitarily formed therewith, without departing from the spirit and scope of the present invention. For example, the pivot member may be stamped or formed from sheet metal with wings or projections similar to end portions 18 b , 18 c of anti-tamper member 18 , with the main body portion 18 a replaced by the pivot member itself.
Pivot member 16 is selectively held in the closed position by lock bar 20 , which includes a locking portion 32 that is engaged by a seal (such as a strap-type seal), a latch, a shackle, a lock (such as a padlock), or the like. Pivot member 16 is thus positionable relative to hinge plate 14 by grasping lock bar 20 and pushing or pulling the lock bar to reposition pivot member 16 . When pivot member 16 and lock bar 20 are in their closed position, lock bar 20 may be locked or latched at locking portion 32 , thereby preventing further movement of lock bar 20 and pivot member 16 and positioning anti-tamper member 18 to prevent access to fasteners 26 . Optionally, end caps 36 may be provided at lock bar 20 to limit or prevent entry of water and debris into lock bar 20 , which may be a hollow tubular member, for example.
Hinge assembly 12 is made from any suitably strong, tamper-resistant material, such as high strength steel, stainless steel, high strength aluminum alloy, or the like. Preferably, anti-tamper member 18 is made of sufficiently strong material, such as high strength steel, in order to resist flexing or grinding.
Changes and modifications to the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law including the doctrine of equivalents. | A hinge assembly incorporates an anti-tamper member that is selectively positionable to protect fasteners holding the hinge assembly to a mounting surface such as an access door. The hinge assembly may be incorporated into a bar lock assembly to provide additional tamper resistance for a shipping container, for example, to limit or prevent unauthorized access to the container. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a class of nitrogenous compounds as antimicrobial agents for the control of bacterial and fungal growth.
2. Description of the Prior Art
Considerable effort has been directed during the past several decades towards developing antimicrobial agents having a high activity against a broad spectrum of microorganisms including bacteria and fungi, but which at the same time exhibit acceptably tolerable physiological properties. It is generally accepted that hexachlorophene of all of such antimicrobials proposed to date comes about the closest to meeting these desiderata. Unfortunately the use of halogenated compounds of this type has been severely restricted because of the recent unfortunate events stemming from what many feel amounted to a conspicuous misuse of hexachlorophene. Accordingly a present need exists for an effective antimicrobial of this type devoid of the chemical characteristics associated with the indicated halogenated compounds.
It has recently been reported that certain fatty amines and fatty amides evidence antimicrobial activity. Although the activity of these compounds fails to measure up to that demanded for a practical antimicrobial agent, the low order of toxicity attributed to compounds of this type renders these findings highly significant.
SUMMARY OF THE INVENTION
In accordance with the present invention a method is provided for inhibiting the growth of bacteria and fungi which comprises applying to said organisms or their loci an antimicrobially effective amount of a compound of the formula ##EQU1## wherein R represents a C 11 - C 17 straight chain aliphatic hydrocarbon group and R' represents methyl, 2-hydroxyethyl or 2-hydroxypropyl.
The antimicrobial agents of this invention in essentially micro concentrations exhibit surprisingly effective broad spectrum inhibitory activity against gram positive and fungal organisms. Moreover, the dipolar ion characteristics of these compounds contribute towards their marked hydrophilic nature and neutrality, which properties are important in numerous use appliations especially where detergency constitutes an adjunct function.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As indicated previously the practice of this invention resides in the use of the antimicrobial agents described above as the active ingredient in a variety of conventional compositions for medicinal, cosmetic, or disinfectant purposes. These compositions can be in the form of solutions, as well as solid, liquid or pasty suspensions and emulsions wherein the carrier or vehicle portion is water, oil, or an organic solvent, such as, for example, ethanol. Likewise these compositions can be solid admixtures including the pulverulent form thereof.
Representative of the foregoing compositions include cosmetic oils, salves, creams, pencils and powders; personal care items such as the spray, stick or powder deodorants, mouthwashes, hair rinses, skin lotions, foot powders and the like; and cleaning compositions such as detergent bars, shampoos and toothpastes. Further, the antimicrobial agents of this invention can be advantageously employed in washing, rinsing, cleaning, disinfecting and preserving compositions for textiles, leather, etc. Still a further important use of these agents can be found in the cleaning and disinfecting compositions designed for use in hospitals and such cleanliness sensitive industrial establishments as dairies, breweries and laundries. The amount of the antimicrobial agent present in the contemplated compositions obviously depends on the particular use for which the overall composition is designed. Generally, in toothpaste, deodorants, cosmetics and foot powders and the like the amount of the antimicrobial agent ranges from about 0.1 to 3.0% based on the total weight of the composition. In applications of a cleansing or disinfecting nature as noted above, the concentration of the agent in these instances can range up to about 10%.
The contemplated antimicrobial compounds of this invention wherein the indicated R' substituent is a hydroxy alkyl group can readily be prepared by reacting approximately stoichiometrical proportions of an applicable fatty acid ester, preferably a lower alkyl ester thereof, 1,1-dimethyl hydrazine and either ethylene or 1,2-propylene oxide. Examples of the applicable fatty acids for deriving a suitable ester thereof include lauric, myristic, palmitic, margaric, stearic and oleic. These acids are preferred since they are present in naturally occurring triglyceride oils and thus are readily and economically obtained from such sources.
The reaction can be effected simply by heating the indicated reactants at a temperature preferably between 20° and 80° C. and recovering the product by the usual crystallization procedures. Complete details relative to the above-described method for deriving the contemplated aminimides can be found in U.S. Pat. No. 3,485,806.
Those aminimides useful in the practice of the present invention wherein the indicated R' substituent is a methyl group can be prepared by several methods. The classical method is applicable for this purpose, which procedure consists of reacting a fatty acid chloride with 1,1-dimethyl hydrazine followed by quaternizing the resultant acid hydrazide with a methyl halide and thereupon treating with a strong base to effect dehydrohalogenation with the resultant production of the desired aminimide. An alternate and more efficient manner of preparing the instantly considered aminimides consists of reacting an ester of an applicable fatty acid, preferably the lower alkyl esters, with approximately an equivalent proportion of a trimethyl hydrazinium halide in the presence of an equivalent proportion of a strong base. Complete details regarding this improved process can be found in U.S. Pat. No. 3,706,800.
EXAMPLE
For the purpose of illustrating the antimicrobic activity of the aminimides of the present invention, five gram positive bacteria and two repesentative fungi were used in a conventional test procedure for determining inhibitory effect. The identification of these test organisms and their source follows:
Organism Source______________________________________Streptococcus faecalis (grp. D) Clinical IsolateStreptococcus pyogenes Clinical IsolateStaphylococcus aureua Hospital InfectionCorynebacterium ATCC No. 10700Nocardia asteroides ATCC No. 3308Saccaharomyces cerevisiae FleishmanCandida albicans Michigan State University Plant Pathology Fungi Collection______________________________________
In the test procedure observed, representative aminimides were dissolved in water or 95% ethanol to provide standard solutions having a concentration of 1.0 mg of the test compound per ml of the solvent. A further test series was prepared by diluting with sterile Trypticase Soy Broth to concentrations of 100 ug/ml. Compounds more active than at 100 ug/ml were further diluted in a subsequent test or tests.
Following the preparation of the test solutions as noted above, one drop (0.04 ± 0.01 ml.) of an 18-hour broth culture containing 10 9 to 10 12 organisms per ml. was added to about 10 cc of each starting dilution of the indicated test compounds as well as to a like sample of plain broth serving as a positive control. After innoculation, the test samples are thoroughly mixed and then incubated at 35° C. in a 5% carbon dioxide atmosphere.
After an 18 hour period of incubation, the minimal inhibitory concentration (MIC) of each compound was determined for each test microorganism. The MIC value is defined as the lowest concentration (ug/ml) of the test compound at which no microscopic evidence of growth is observed. In the instances where the MIC exceeded 1000 ug/ml the compound was rated non-inhibitory (NI). Under those circumstances where the test compound itself causes turbidity so that the MIC proved difficult to determine in accordance with the above procedure, a sample (0.015 ml.) of the well-agitated broth or broths in question were innoculated into a Trypticase Soy agar plate containing 5% defibrinated sheep blood. The test plate would then be incubated at 35° C. for 18 hours and thereupon examined for growth.
The identification of representative compounds tested in accordance with the following procedure together with the results obtained are outlined in the following Tables.
TABLE I______________________________________ OCH.sub.3 OH ∥.sup.-.sup.+|| CH.sub.3 (CH.sub.2).sub.n --C--N--N----CH.sub.2 --CH.sub.2 | CH.sub.3COMPOUND - n = 10 12 14______________________________________Streptococcus faecalis (grp. D) 100 10 100Streptococcus pyogenes 100 10 10Staphylococcus aureus 100 10 10Corynebacterium sp. 100 10 10Nocardia asteroides 100 10 10Candida albicans 100 10 10Saccharomyces cerevisiae 100 10 10______________________________________
TABLE II______________________________________ OCH.sub.3 OH ∥.sup.-.sup.+|| CH.sub.3 (CH.sub.2).sub.n --C--N--N----CH.sub.2 CH--CH.sub.3 | CH.sub.3COMPOUND - n - 10 12 14 16 16*______________________________________Streptococcus faecalis 100 100 100 100 1000(grp. D)Streptococcus pyogenes 10 10 10 10 1Staphylococcus aureus 100 10 10 100 10Corynebacterium sp. 10 10 10 10 10Nocardia asteroides 100 10 10 100 100Candida albicans 100 10 10 1000 1000Saccharomyces cerevisiae 100 10 10 100 10______________________________________ *From oleyl
TABLE III______________________________________ O ∥.sup.-.sup.+ CH.sub.3 (CH.sub.2).sub.n --C--N--N(CH.sub. 3).sub.3COMPOUND - n = 10 12 14______________________________________Streptoccus faecalis (grp. D) 1000 100 10Streptococcus pyogenes 1000 10 10Staphylococcus aureus 1000 10 10Corynebacterium sp. 1000 10 10Nocardia asteroides 1000 10 10Candida albicans 1000 100 10Saccharomyces cerevisiae 1000 10 10______________________________________ | A class of aminimides structurally characterizable as dipolar ions wherein a quaternary nitrogen atom is directly bonded to the nitrogen anion of a long chain fatty amide exhibit broad spectrum inhibitory activity against gram positive bacteria and fungi. | 0 |
BACKGROUND
1. Field of the Invention
This invention relates to solenoids, in general, and to latching solenoids in particular and, especially, latching solenoids which are magnetically latched.
2. Prior Art
There are many electro-magnetic devices known in the prior art. Many of these electro-magnetic devices take the form of coils of wire mounted on cores, usually of ferromagnetic material. In many cases the devices take the form of relays which move armatures relative to the core in response to an electrical signal applied to the coil.
These types of devices are often referred to as switches or relays.
In related devices, the core, per se, moves with respect to the coil and effects an action as a result of the movement of the core. These devices are normally referred to as solenoids.
In most solenoids, an electrical signal is applied to a coil which generates electro-magnetic flux in a core. The flux operates to move the core relative to the coil and to effect a work function or operation. However, in many cases the moveable core remains in the position only in response to the application of the electrical signal to the coil. The solenoid mechanism does not latch in any particular position.
In order to provide a latching arrangement in most solenoids known in the art, it is requried to provide a separate electro-mechnical latching mechanism. However, the devices known in the prior art are subject to various problems and tend to lack reliability.
Typically, a solenoid is defined as an electrically energized coil which may consist of one or more layers of winding. It is the basis of most forms of electro-magnets and is, thus, part of the operating mechanism of many operating devices. One of the simplest forms and, at the same time, widely used form of solenoid is the so-called plunger-type solenoid. In this apparatus a coil is wound on a non-magnetic form or bobbin which includes a central (axial) opening in which a magnetic plunger may move. Application of an energizing signal to the coil pulls the plunger up into the coil and, thus, operates the associated mechanism. An iron-clad solenoid is similar except for an iron case which surrounds the coil. This iron case operates on the flux and increases the magnetic pull of the plunger. Other types of solenoids use a fixed core and various types of armatures. Solenoids are widely used for operating circuit breakers, track switches, valves and many other mechanical devices.
Consequently, it is highly desirable to have a relatively simple yet highly reliable solenoid device wherein a simple latching condition can be provided.
PRIOR ART STATEMENT
A preliminary search was conducted by applicant. The results of the search are presented herewith. The patents are listed in numerical order and no special significance is attached thereto.
U.S. Pat. Re. No. 24,209; NEUTRAL RELAY; A. C. Bernstein. This patent is directed to an electromagnetic relay which is magnetically biased to a neutral position.
U.S. Pat. No. 698,027; POLARIZED MAGNET; E. C. Knapp. This patent is directed to a polarized magnetic device having the two ends thereof branched or forked into a pair of magnetic poles of the same polarity.
U.S. Pat. No. 1,552,676; ELECTROMAGNETIC APPARATUS; R. E. H. Carpenter, et al. This invention is directed to an electromagnetic motor apparatus for use as a relay in which a pivotally supported armature is arranged in a space between the poles of an otherwise complete signal magnetic circuit system.
U.S. Pat. No. 2,483,658; POLARIZED ELECTRO-MAGNETIC RELAY; C. F. Miller. This patent is directed to a polarized relay which includes a permanent magnet and an electromagnet with a moveable armature which is positioned as a result of an electromagnetic current direction.
U.S. Pat. No. 3,968,470; MAGNETIC MOTOR; J. M. Brown. This invention is directed to a magnetic motor for use as an actuator in a relay and includes an electromagnetic winding which has a core member on the opposite ends of which are fastened pole pieces which cooperate with a magnetically moveable armature.
U.S. Pat. No. 4,020,433; RELEASE TYPE ELECTROMAGNETIC DEVICE; M. Uchidoi, et al. This patent is directed to a device which includes a permanent magnet for attracting a moveable iron armature with a permanent magnet sandwiched between two magnetic members and magnetizing windings which embrace each magnetic member between the permanent magnet and the pole faces thereof.
U.S. Pat. No. 4,236,132; ELECTROMAGNETIC SWITCH MEANS FOR A FLOW CONTROL DEVICE AND THE LIKE HAVING REDUCED SHOCK LEVELS; N. Zissimopoulos. This patent is directed to an electro magnetic switch which includes an armature which is pivotally moveable between first, second positions about a fulcrum. Magnets are positioned adjacent each of the armature ends so that the armature can be moved by changing polarity of an electromagnetic core means.
U.S. Pat. No. 4,286,244; ELECTROMAGNETIC ACTUATOR FOR A LATCH RELAY; J. P. Schuessler. This patent is directed to a polarized relay in which the poles of an electromagnet are project toward an armature on either side of a pivot support which allows the armture to pivot toward one pole or the other. A pair of permanent magnets share one pole respectively with the poles of the electromagnet.
U.S. Pat. No. 4,316,167; ELECTROMAGNET WITH A MOVING SYSTEM AND PERMANENT MAGNET, ESPECIALLY FOR CONTACTORS; G. N. Koehler. This patent is directed to a device including a permanent magnet and pole pieces which are accurately guided in axial translational motion within a coil unit. Air-gap zones are located at both ends of the coil unit and a stationa yoke surrounds the two ends of the coil.
U.S. Pat. No. 4,604,599; ELECTROMAGNET COMPRISED OF YOKES AND AN ARMATURE SUPPORTING A PERMANENT MAGNET FITTED ON ITS POLE FACES WITH POLE PIECES THAT PROJECT FROM THE AXIS OF THE MAGNET, THE AXIS BEING PERPENDICULAR TO THE DIRECTION OF MOVEMENT; G. N. Koehler. This patent is directed to an electromagnet which includes yokes which are moveable in relation to an armature and winding surrounding a part of the magnetic circuit. The armatures comprise a magnet fitted with two pole pieces which project past both extremities of the magnet in order to define the air-gap forces. A second armature is also used and is located parallel to the first armature.
U.S. Pat. No. 4,609,899; POLARZIED ELECTROMAGNET HAVING THREE STATES AND A CONTROL CIRCUIT FOR SAID ELECTROMAGNET; G. N. Koehler. This patent is directed to a three-state polarized electromagnet comprising a stationary system surrounded by a coil and a moving system which incorporates a permanent magnet fitted with pole pieces which are bent backwards towards each other to define four air-gaps.
U.S. Pat. No. 4,730,175; POLARIZED ELECTROMAGNET DEVICE; P. Ichikawa et al. This patent is directed to a polarized electromagnet device with a magnetic block moveable within a specially designed yoke in response to the attraction forces of permanent magnets and an electromagnetic coil.
U.S. Pat. No. 4,814,732; MAGNETIC LATCHING ACTUATOR: G. B. Pratt. This patent is directed to a magnetic latching actuator which has a core having at least one electrical coil thereon. The magnet is positioned against a U-shaped magnetic flux connector having two parallel plates. The plates are sufficiently spaced from each other to permit passage of the U-shaped armature therebetween. The armature includes two ends which are designed to alternately engage the core at opposite ends.
SUMMARY OF THE INSTANT INVENTION
This invention is directed to a latching solenoid which includes a plurality of magnetic paths. The magnetic paths interact to provide a solenoid apparatus wherein a plunger can be moved relative to a coil. More importantly, the plunger is caused to latch in a particular position. That is, the plunger can be moved, axially, in either direction relative to a coil. It can be latched in specified positions as a result of magnetic operation even though the energizing signal is removed from the coil. The solenoid includes a pair of magnetic circuit paths in which magnetic flux fields are created by permanent magnets. In addition, supplemental magnetic flux fields are created in the magnetic circuit paths as a result of the application of the energizing signal to the coil. The supplemental magnetic flux field created by the signal is used to move the plunger from one latched position to the other. Permanent magnetic flux fields are used to retain the plunger latched in the particular position which was dictated by the application of the electrical signal.
A subsequent electrical signal, of opposite plurality, is required to move the plunger to a different rest position at which time the plunger is magnetically latched again. The operation is then sequential and controlled by the application of electrical signals to the coil.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of one embodiment of the instant invention in a first rest position.
FIG. 2 is a schematic representation of the first embodiment of the instant invention shown in a second rest position.
FIG. 3 is a schematic representation of one end view of the embodiment of the invention shown in FIGS. 1 and 2.
FIG. 4 is a schematic representation of another embodiment of the instant invention shown in a first rest position.
FIGS. 5 and 6 are opposite end views of the embodiment shown in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown a schematic representation of one embodiment of the instant invention. In FIG. 1, the representation is a partially sectional, partially broken away view of the solenoid 100. The solenoid includes a plunger which comprises a central shaft 101 which is formed of magnetizable or magnetic material. Typically, the shaft or core 101 is substantially cylindrical in configuration. End pieces 102 and 103 can be formed at the respective ends of core 101 if so desired. As shown, the end pieces 102 and 103 are of smaller diameter than the core piece 101. Typically, the end pieces 102 and 103 are used to abut against and activate a mechnical device such as an electrical contact or the like. The end pieces, per se, form no portion of the invention and can be omitted, if necessary.
In addition, in the embodiment shown in FIG. 1, a pair of tabs 104 and 105 extend radially from the surface of the core 101. The tabs 104 and 105 can be integrally formed with core 101 or can be fabricated of substantially similar material and attached to the core in a suitable fashion such as welding or the like. The tabs 104 and 105, which can be considered as core pole pieces, extend outwardly from opposite sides of the outer surface of core 101.
The coil 107 which comprises of plurality of windings of electrically conductive material such as wire or the like and is wound on a suitable support bobbin 106. The bobbin 106, typically, formed of non-magnetic, non-conductive material and is arranged to have a central axial opening therethrough. The core 101 is arranged to be moveably mounted within the central opening in bobbin 106. Thus, core 101 can move or slide relative to the bobbin 106.
In addition, there are a plurality of magnetic flux paths arranged relative to the core 101. In particular, at least two separate flux paths are arranged on different sides of the core. In the embodiment shown in FIG. 1, these magnetic flux paths 120 and 125 are arranged on opposite sides of the core. Other arrangements can, of course, be provided and such arrangements are contemplated within this invention.
More particularly, each of the flux paths 120 and 125 includes a typical north pole and a south pole. In the embodiment shown, a permanent magnet 109 is provided substantially centrally positioned in the flux path 120. A pair of pole pieces 110 and 111 are affixed to or mounted at the ends of the permanent magnet 109. Thus, pole pieces assume the north (in this case pole piece 110) and south (in this case pole piece 111) poles as determined by the magnet 109.
A similar but opposite arrangement is provided on the other side of the apparatus. In this instance, a permanent magnet 108 is mounted together with the pole pieces 112 and 113. The pole piece 113 is determined to be the north pole while the pole piece 112 is determined to be the south pole. The north and south pole arrangements as related to magnets 108 and 109, is opposite. Thus, the north pole piece 113 and south pole piece 111 are arranged adjacent to the end piece 103 of the core 101. Conversely, the north pole piece 110 and south pole piece 112 are associated with the end piece 102 of the core 101.
The coil 107 is connected to any suitable source 114 which will, from time-to-time, provide energizing pulses to the coil 107.
While they are not shown in FIG. 1 appropriate support means and the like are provided in any suitable fashion.
To better understand the mechanical arrangement of the apparatus, concurrent reference is made to FIG. 3. In this case, the solenoid 10 includes the bobbin 106, the coil 107 mounted on bobbin 106. The end piece 102 is shown relative to the core 101. The core pole piece 104 extends outwardly, to the right in the illustration, from the core 101. The pole pieces 110 and 112 extend from the respective magnets 109 and 108 inwardly toward the core 101. A suitable base 150 is shown schematically and operates to support the components of the apparatus. Of course, any other suitable mounting arrangement can be made. Moreover, as shown in FIG. 3, the magnets 108 and 109 are relatively large. The pole pieces 110 and 112 could, alternatively, be enlarged and the permanent magnets 108 and 109 can be reduced in size.
Conversely, it is conceivable that the pole pieces 110, 111, 112 and 113 could, in fact, be fabricated of and formed integrally with the permanent magnets 108 and 109. It is not essential that separate pole pieces be utilized. However, the configuration of the magnets and the related pole pieces is a function of economics and/or design.
Referring again to FIG. 1, the magnetic flux paths are depicted in the apparatus and represented by the arrows and the lines 120 and 125. Because of the relationship of the permanent magnets 108 and 109 and the respective pole pieces, the magnetic flux paths are provided in opposite directions in the apparatus. In particular, the magnetic flux produced in core 101 by the respective permanent magnets 108 and 109 is clearly in the opposite direction.
In the embodiment shown in FIG. 1, the magnetic flux path 125 is, of course, inherently stronger than the flux 120. That is, in the rest position shown, referred to as gap B i.e. the gap between pole piece 104 and pole piece 112 is a minimal dimension. In point of fact, the pole pieces 104 and 112 may be in contact so as to provide a substantially closed magnetic flux path.
Conversely, gap A between pole pieces 111 and 105 is open and spaced apart thereby developing an air gap therebetween. The air in gap A inherently adds a significant reluctance to the magnetic flux path and, therefore, significantly reduces the strength of the magnetic flux in the flux path.
That is, the permanent magnets 108 and 109 are substantially identical magnets. The remainder of each of the flux paths is substantially identical in length, width, type of material and so forth. The only difference between the two flux paths is the spacing developed at gap A and gap B. Because gap A is a relatively large air gap, the magnetic field through flux path 120 is significantly reduced. Consequently, the flux path assciated with pole piece 112 and so forth is a stronger field and maintains the plunger, i.e. core 101, latched in the configuration shown in FIG. 1.
In the event that an electrical signal is supplied by source 114 across terminals X1 and X2, the coil 107 is energized and produces its own magnetic flux field. Depending upon the polarity of the signal applied to coil 107, the flux field produced by coil 107 is in the same direction as shown for either flux path 120 or 125. This coil induced field enhances the flux which is co-directional. Thus, if the coil 107 produces a flux in the direction of flux 125, core 100 remains in the condition shown.
In the event that the signal supplied by source 114 is of the opposite plurality, i.e. it is of the appropriate polarity to cause coil 107 to produce a field which is superimposed upon and enhances the field produced by permanent magnet 109, the magnetic field through pole piece 110 and so forth, is enhanced. This modification of the magnetic fields is operative to enhance the attraction between pole pieces 105 and 111 and thus to overcome the attraction between pole pieces 104 and 112. (Depending upon the size of the field produced by the coil 107, there may actually be repulsion between pole pieces 104 and 112.)
As a consequence of the enhanced or modified field, the plunger 100 including core 101 is moved so that pole pieces 105 and 111 are attracted to each other. Thus, gap A is closed. Concurrently, pole pieces 104 and 112 move away from each other and gap B becomes an air gap. This latter configuration is shown in FIG. 2.
Referring now to FIG. 2, there is shown a second rest position for this embodiment of the invention. The structure shown in FIG. 2 is identical to the structure shown in FIG. 1. However, this rest position represents the rest position after a signal has been supplied by the source 114 to coil 107 and of such plurality so as to enhance the magnetic flux 120. Thus, the core 101 or plunger of the solenoid has been pulled upwardly or to the right as shown in FIGS. 1 and 2. The gap A between pole pieces 111 and 105 has been reduced to, effectively, zero while gap B has been increased. In essence, gap B, (as shown in FIG. 2) is substantially identical to gap A as shown in FIG. 1. In this instance, the magnetic flux paths remain substantially the same. However, the reluctance in the flux path 125 is now larger than the reluctance in the flux path 120. This is the reverse of the situation shown and described relative to FIG. 1. However, because of the flux produced in the respectiv epaths by the permanent magnets, the solenoid will now remain at rest in the position shown in FIG. 2 until caused to reset by the application of a signal by source 114. This signal will be, of course, of opposite polarity to the signal which was supplied by source 114 to cause the plunger to move from the position shown in FIG. 1.
Referring now to FIG. 4, there is shown another embodiment of the instant invention. Again, the configuration is quite similar to configuration shown in FIG. 1. For example, a core 401 is mounted in the central opening of a coil 407 which is wound on a suitable bobbin 406. In this embodiment, the permanent magnets 408 and 409 are provided at one end of the solenoid. This is not an absolute requirement but is used to show an alternative arrangement relative to the arrangement shown in FIG. 1. In this embodiment, the side walls 410 and 412 are formed of magnetizable material which provide portions of the flux paths. They also operate as pole pieces. The pole pieces 414 and 413 are provided at the end of the side pole pieces 410 and 412, respectively.
The core 410 includes the armature tabs 405 and 404, respectively. However, it is noted that the armature tabs 404 and 405 are mounted at the same end but on opposite sides of the core 401. This arrangement permits easier construction of the solenoid and repair, if necessary, of the core apparatus.
It is noted that the armature apparatus is arranged so that the armature tabs will be equally distant from the pole pieces 411 and 413 when the armature is moved from one rest position to the other.
The flux paths 420 and 425 are shown. These flux paths have substantially the same function and operation as the flux paths 120 and 125 as shown in FIGS. 1 and 2. The flux paths are, in essence, developed by the permanent magnets 408 and 409 in conjunction with the remainder of the magnetic flux path components. The magnetic flux is selectively altered by the application of a signal to the coil 407 in the same fashion as shown in FIG. 1. Thus, the respective flux patterns are altered so that the core 401, together with the armature tabs, moves with respect to the coil 407 to selectively achieve and maintain a rest position.
As is the case in the embodiment shown in FIG. 1, the rest position controls the position and location of the end piece 403 (or a counterpart end piece 402, if so desired) thereby to move, position, locate or the like a set of contacts, a relay armature, or similar utilization device.
As shown in FIG. 4, supports 430 and 431 are shown. Typically, the supports 430 and 431 are fabricated of a non-magnetic materials such as brass, teflon, delrin or the like and may include suitable bearings or bearing surfaces fabricated of nylon, delrin or similar material.
Referring to FIG. 5, there is shown one end of the embodiment shown in FIG. 4. In this instance, the core 401 is mounted to pass through an aperture in an end pole piece 450 which is mounted between the permanent magnets 48 and 409. The magnets 408 and 409 are mounted to pole pieces 412 and 410, respectively. The components shown in FIGS. 4 and 5 may be held together by appropriate screws, welds or any other suitable arrangement.
Referring now to FIG. 6, there is shown the other end of the solenoid 400 as shown in FIGS. 4 and 5. Again, the side pieces 412 and 410 are mounted at the outer edges of the unit. The pole pieces 411 and 413 are mounted to the side pieces 410 and 412, respectively. The pole pieces can be mounted in any suitable fashion and, in some cases, may be integrally formed with the respective side pieces.
The end piece 403 of the core 401 extends outwardly from the plane of the illustration. The armature tabs 404 and 405 extend radially outwardly from the surface of core 401. The core is arranged to move axially through the opening in coil 407 which is mounted on bobbin 406. In the embodiment shown in FIG. 6, a suitable support which is fabricated of a low friction, non-magnetic material such as brass, teflon, delrin or the like may be provided.
Again, the operation of the plunger of the two embodiments is controlled by the application of an electrical signal to the coil which produces a magnetic flux which enhances one of the flux paths produced by the permanent magnets in the magnetic structure. Thus, the plunger of the solenoid is selectively caused to move. Moreover, after the plunger has moved, it is maintained or latched in a "rest" position solely due to the flux produced by the permanent magnet pending the application of another control signal to the electromagmetic coil.
Thus, there is shown and described an improved solenoid construction. This construction permits selective movement of a solenoid plunger and also permits the plunger to be retained in a latched position in the absence of an electrical control signal. Thus, a one shot operation or a semi-permanent control position is achieved. The construction shown and described above is intended to be illustrative only. It is not intended to be limitative. Those skilled in the art may conceive modifications or variations to the concept as shown and described. However, any such modifications or variations which fall within the description of this invention are intended to be included therein as well. Thus, the scope of the invention is limited only by the claims appended hereto. | A latching solenoid which effects latching through a magnetic flux arrangement rather than a electromechanical latching mechanism. An electro-magnetic arrangement is used to move the solenoid from one latched position to the other. | 7 |
This application is a U.S. National Stage Application under 35 U.S.C. §371 of International Patent Application No. PCT/KR2010/007522, filed 29 Oct. 2010, which claims the benefit of priority to South Korean Patent Application No. 10-2009-0106113, filed 4 Nov. 2009, the disclosures of all of which are hereby incorporated by reference in their entireties. The International Application was published in Korean on 12 May 2011 as WO 2011/055931. To the extent appropriate, a claim of priority is made to each of the above disclosed applications.
TECHNICAL FIELD
The present invention relates to a herbal extract useful for the prevention and/or treatment of influenza virus-induced diseases, more precisely, to a herbal extract that is very effective in preventing and/or treating influenza virus-induced diseases, particularly those infecting human.
BACKGROUND
Influenza virus is a RNA virus belonging to Family Orthomyxoviridae which causes inflammation in respiratory system. This is a highly infectious virus that infects others via direct communication through air from cough or saliva of the infected ones or via indirect communication through anything that is touched by the infected ones. The incubation period of this virus is 24˜30 hours and serotype of the virus is divided as type A, type B, and type C. Type B and type C are confirmed to infect only human, while type A can infect not only human but also various species of mammals including horse, pig, and others, and also various species of domestic poultry and wild birds (Selmons et al., Avian Dis., 18(1), p. 119-124, 1974; Webster R G et al., Microbiol Rev., 56(1), p. 152-179, 1992).
The classification of serotype of type A influenza virus depends on the two kinds of proteins observed on the surface of the virus, which are Hemagglutinin (HA) and Neuraminidase (NA). Type A virus can be divided into 144 different serotypes (16 kinds of HA and 9 kinds of NA). HA aids the virus to be attached on somatic cells, while NA helps the virus to invade into the cells (Alexander D J, Vet. Microbiol., 74(1-2), p. 3-13, 2000). The natural normal host for type A influenza virus is wild water birds such as duck and seagull. From the epidemiological studies of influenza virus infection in wild birds over the world, it was confirmed that all the existing 16 kinds of HA and 9 kinds of NA were found in wild birds (Selmons et al., Avian Dis., 18(1), p. 119-124, 1974). Avian influenza virus classified as type A is the zoonosis virus which is divided into three major groups (Alexander D J, Vet. Microbiol., 74(1-2), p. 3-13, 2000); which are non-pathogenic avian influenza that causes light respiratory symptoms when it infects chickens, low pathogenic avian influenza (LPAI) that causes 1˜30% mortality and egg drop syndrome, and highly pathogenic avian influenza (HPAI) called “Bird Flu” that shows high lethality of at least 95%. Particularly, HPAI is classified as List A disease by OIE (Office International des Epizooties) and as 1 st class contagious animal disease in Korea.
Since 1980s, HPAI has been reported world-widely including USA (1983), Australia (1985, 1992, 1994 and 1997), Mexico (1994), Pakistan (1994 and 2004), Hong Kong (1997 and 2001), Italia (1997 and 1999), Netherland (2003), Belgium (2003), Germany (2003), and Canada (2004). In addition, starting with Korea (December, 2003), almost all the East-South Asian and Far East Asian countries including Vietnam, Japan, Thailand, Cambodia, Laos, Indonesia, and China reported the break-out of serotype A/H5N1 HPAI all at the same time in 2004. In particular, HPAI broken out in Vietnam and Thailand, unlike typical HPAI broken out in Korea and Japan at that time that has been characterized as not being infectious to human, was confirmed as a mutant avian influenza (mutant A/H5N1 HPAI) that was infectious to human via contact with infected birds. As of March, 2004 in Vietnam, 15 out of 22 people infected with the mutant form by the contact with the infected birds were dead and 8 out of 11 people were also killed in Thailand as well, worrying all the countries. The frequency of HPAI outbreak is 10 times higher than before. Since 2001, HPAI outbreak has been reported every year world-widely. Therefore, it is required to develop a novel prevention method which is effective in controlling HPAI (Song C S et al., Korean J. Poult. Sci., 31(2), p. 129-136, 2004).
Some serotypes of influenza virus, which causes problems in birds, cause even death in human after developing flu symptoms. Some mutant forms originated from three serotypes of avian influenza virus such as A/H7N7, A/H9N2, and A/H5N1 so called “Hong Kong avian influenza” are assumed to be infectious to human. Therefore, studies on such mutant virus forms originated from the above three serotypes have been eagerly going on word-widely (Suarez D L et al., J. Virol., 72(8), p. 6678-6688, 1998).
In the meantime, novel influenza that has been now prevailing all over the world since it was first found in Mexico in spring of 2009 is influenza type A subtype H1N1 having type 1 hemagglutinin (H1) and type 1 neuraminidase (N1) (Hereinafter, the said novel influenza A virus is called ‘2009 NIH1 influenza virus’). The 2009 NIH1 influenza virus is a kind of virus in which genetic materials of influenza viruses originated from human, swine, and birds are mixed. At this time swine is called as “mixing vessel”. Thus, it was first named as swine influenza. However, since there was no proof saying that this virus is directly delivered to human from infected swine or delivered to swine from infected human or related to swine whatsoever, WHO used to call it novel influenza A (H1N1). From the sequence analysis of 2009 N1H1 influenza virus, it was confirmed that HA gene includes a certain sequence that is infectious to human, suggesting the possibility of infecting human. HA gene does not contain dibasic amino acid, the typical amino acid of highly pathogenic virus, but comprises drug resistant gene against amantadine and rimantadine. The virus was also confirmed not to have any mutation in NS1 and PB2 genes in relation to pathogenicity, suggesting that the virus was not highly pathogenic. 2009 NIH1 influenza virus is infectious through respiratory system and is highly contagious compared with the conventional influenza A virus. The symptoms of this virus are similar to those of the conventional influenza virus, for example high fever, cough, etc. To prevent the infection, personal hygiene including hand-washing and wearing a mask is required. It is recommended to treat the virus infection to use antiviral agents such as Tamiflu and Relenza.
Once infected with influenza virus, each organ in respiratory system loses its resistance, resulting in the development of complications such as bronchitis, laryngopharyngitis, and pneumonia. Particularly, chronic disease patients, aged people, children, and long-term hospitalized patients are in high risk since their immunities are very weak. Therefore, studies to prevent influenza are going on in the aspects of biosecutity and influenza vaccine. However, to get vaccine shot, proper timing is important as well as the prediction of the kind of prevailing influenza virus, which are troublesome.
Efforts have been made world-widely to develop an antiviral agent. Up to date, lamibudine used for the treatment of HIV-1 and hepatitis B, gancyclovir used for the treatment of herpes virus infection, and ribavirin used for the treatment of respiratory syncytial virus infection and also used for the urgent care of diverse virus infections have been approved and now are on the market. In addition, amantadine approved for the treatment of influenza virus A and its analogue rimantadine, zanamivir (Relenza) artificially synthesized as an influenza virus neuraminidase inhibitor, and oseltamivir (TAMIFLU™) are also on the market. Amantadine and rimantadine are designed to inhibit the functions of M2 ion channel protein of influenza virus, which are representative antiviral agents suppressing in vivo proliferation of influenza virus. These two antiviral agents are only effective for serotype A influenza virus and not effective at all for serotype B influenza virus that does not contain M2 protein. There is another problem in using amantadine and rimantadine. That is, with the use of those drugs, a mutant virus is easily generated whose M2 ion channel protein is not affected by those drugs. Zanamivir and oseltamivir, developed to overcome the above problem, are designed to inhibit the functions of neuraminidase, which became representative antiviral agents inhibiting the proliferation of influenza virus in vivo. These two antiviral agents are known to be effective in inhibiting all of 16 kinds of serotype A influenza virus and all of serotype B influenza virus. However, zanamivir needs to be inhaled or injected intravenously, which is not an easy pathway. In the meantime, oseltamivir can be orally administered, but according to the recent reports, side effects such as vomiting and dizziness are accompanied with the oral administration and resistant virus has been also generated (Ward P et al., J. Antimicrob. Chemother., 55(suppl), p. i5-i21, 2005). Therefore, it is important to develop a safe natural agent along with the vaccine and therapeutic agents to increase human immunity and to reduce death rate upon pandemic of such virus.
To treat influenza in Oriental Medicine, different kinds of medicinal herbs are boiled together and the extract therefrom is used, which is exemplified by Insampaedoksan, Gumiganghwalsan, Galgeun-tang, Mahwang-tang, Daecheongryong-tang, Seungmagalgeun-tang, Chungjogupae-tang, Yihyangsan, and Baekhogainsam-tang. Many kinds of medicinal herbs are used, and these are more to increase immunity of human body than to act as an antiviral agent. Thus, it is urgent request to develop a novel drug to prevent and/or treat influenza virus-induced disease more fundamentally.
Thus, the present inventors investigated the effect of medicinal herbs used in Oriental Medicine on the activity of influenza virus. As a result, the present inventors confirmed that the herbal extract containing Epimedium koreanum had excellent preventive and/or therapeutic effect on diseases caused by various types of influenza viruses, leading to the completion of this invention.
SUMMARY OF THE INVENTION
Technical Problem
It is an object of the present invention to provide a herbal extract containing Epimedium koreanum , and a composition and health food for the prevention or treatment of influenza virus-induced diseases comprising the said herbal extract as an active ingredient.
Technical Solution
To achieve the above object, the present invention provides a herbal extract extracted from herb mixture containing Epimedium koreanum by using water or an organic solvent.
To prepare the herbal extract of the present invention, water or an organic solvent, preferably water, was added to herb mixture containing Epimedium koreanum by 2˜10 times the volume of the herb mixture, followed by extraction at 70˜100° C. for 1˜10 hours or preferably 3˜4 hours. However, the extraction is not limited to the above hot water extraction, and enfleurage, reflux extraction, or ultrasonic extraction can also be used. In addition to Epimedium koreanum , herbs used for the extraction is not limited and any medicinal herb generally used for the purpose of preventing or treating cold or flu in Oriental Medicine can be added without limitation. In this invention, the said organic solvent is exemplified by water, C 1 -C 4 alcohol, C 1 -C 4 ketone, C 1 -C 4 aldehyde and aqueous solution of alcohol, ketone or aldehyde. Among these, water is more preferred.
In this invention, the said influenza virus preferably has the serotype selected from the group consisting of H1N1, H1N2, H2N2, Human B, H3N2, H3N8, H5N1, H5N2, H5N3, H5N8, H5N9, H7N1, H7N2, H7N3, H7N4, H7N7, H9N2, and H10N7, and more preferably has the serotype selected from the group consisting of H1N1, H3N2, Human B, H5N1, H9N2, H7N1, and H7N2, and most preferably has the serotype of H1N1.
The herbal extract of the present invention can be administered orally or parenterally and be used in general forms of pharmaceutical formulation. That is, the herbal extract of the present invention can be prepared for oral or parenteral administration by mixing with generally used diluents or excipients such as fillers, extenders, binders, wetting agents, disintegrating agents and surfactants. Solid formulations for oral administration are tablets, pills, powders, granules and capsules. These solid formulations are prepared by mixing the said herbal extract with one or more suitable excipients such as starch, calcium carbonate, sucrose or lactose, gelatin, etc. Except for the simple excipients, lubricants, for example magnesium stearate, talc, etc, can be used. Liquid formulations for oral administrations are suspensions, solutions, emulsions and syrups, and the above-mentioned formulations can contain various excipients such as wetting agents, sweeteners, aromatics and preservatives in addition to generally used simple diluents such as water and liquid paraffin. Formulations for parenteral administration are sterilized aqueous solutions, water-insoluble excipients, suspensions, emulsions, lyophilized preparations and suppositories. Water insoluble excipients and suspensions can contain propylene glycol, polyethylene glycol, vegetable oil like olive oil, injectable ester like ethylolate, etc. Suppositories can contain witepsol, macrogol, tween 61, cacao butter, laurin butter, glycerol, gelatin, etc.
The herbal extract of the present invention can be administered to mammals such as human, cattle, swine, horses, sheep, rats, and mice, and birds such as fowls and ducks by various pathways. For example, the possible administration pathway can be oral administration, rectal administration, intravenous injection, intramuscular injection, hypodermic injection, intrauterine injection or intracerebroventricular injection. The effective dosage of the herbal extract of the present invention can be determined according to absorption of an active ingredient, inactivation rate, excretion, age, gender, health condition, and severity of a disease. In general, the dosage for adult is 10˜300 mg/kg per day and preferably 20˜100 mg/kg per day, and administration frequency is preferably 1˜6 times a day. The dosage unit can contain, for example, 1, 2, 3 or 4 individual doses or ½, ⅓ or ¼ of an individual dose. An individual dose preferably contains the amount of active compound which is administered in one application and which usually corresponds to a whole, ½, ⅓ or ¼ of a daily dose.
Since the herbal extract of the present invention is a natural substance and has no toxicity, it can be continuously administered at a high dose. The herbal extract of the present invention is evaluated to be a safe substance since its estimated LD 50 value is much greater than 5 g/kg in mice, which is confirmed by toxicity assay with mice tested via oral administration.
In a preferred embodiment of the present invention, the herbal extract of the present invention does not show cytotoxicity at a comparatively high concentration, compared with Tamiflu used as the positive control (see Table 1), but demonstrated antiviral activity against diverse serotypes of influenza virus (see FIG. 1 ). Therefore, the herbal extract of the present invention can be effectively used for the prevention or treatment of influenza virus-induced diseases.
The present invention also provides a health food for the prevention of influenza virus-induced disease or alleviation of its symptoms comprising the said herbal extract as an active ingredient. The health food herein indicates the food with improved functionality, compared with the general food, obtained by adding the herbal extract of the present invention thereto. The functionality herein indicates physical properties and physiological functions. When the herbal extract of the present invention is added to general food, physical properties and physiological functions of the food can be improved and such food improved in functions is described as ‘health food’ inclusively in this invention.
In this invention, the said influenza virus preferably has the serotype selected from the group consisting of H1N1, H1N2, H2N2, Human B, H3N2, H3N8, H5N1, H5N2, H5N3, H5N8, H5N9, H7N1, H7N2, H7N3, H7N4, H7N7, H9N2, and H10N7, and more preferably has the serotype selected from the group consisting of H1N1, H3N2, Human B, H5N1, H9N2, H7N1, and H7N2, and most preferably has the serotype of H1N1.
The herbal extract of the present invention can be added to health food for the prevention of influenza virus induced disease or alleviation of its symptoms. In that case, the herbal extract of the present invention can be added as it is or as mixed with other food components according to the conventional method. The mixing ratio of active ingredients can be regulated according to the purpose of use (prevention, health enhancement or treatment). In general, to produce health food or beverages, the herbal extract of the present invention is added preferably by up to 30 wt % and more preferably by up to 10 wt %. However, if long term administration is required for health and hygiene or regulating health condition, the content can be lower than the above but higher content can be accepted as well since the herbal extract of the present invention has been proved to be very safe.
The food herein is not limited. For example, the herbal extract of the present invention can be added to meats, sausages, breads, chocolates, candies, snacks, cookies, pizza, ramyuns, flour products, gums, dairy products including ice cream, soups, beverages, tea, drinks, alcohol drinks and vitamin complex, etc, and in wide sense, almost every food applicable in the production of health food can be included.
The composition for health beverages of the present invention can additionally include various flavors or natural carbohydrates, etc, like other beverages. The natural carbohydrates above can be one of monosaccharides such as glucose and fructose, disaccharides such as maltose and sucrose, polysaccharides such as dextrin and cyclodextrin, and glucose alcohols such as xilytole, sorbitol and erythritol. Besides, natural sweetening agents such as thaumatin and stevia extract, and synthetic sweetening agents such as saccharin and aspartame can be included as a sweetening agent. The content of the natural carbohydrate is preferably 0.01˜0.04 g and more preferably 0.02˜0.03 g in 100 ml of the herbal extract of the present invention.
In addition to the ingredients mentioned above, the herbal extract of the present invention can include in a variety of nutrients, vitamins, minerals, flavors, coloring agents, pectic acid and its salts, alginic acid and its salts, organic acid, protective colloidal viscosifiers, pH regulators, stabilizers, antiseptics, glycerin, alcohols, carbonators which used to be added to soda, etc. The herbal extract of the present invention can also include natural fruit juice, fruit beverages and/or fruit flesh addable to vegetable beverages. All the mentioned ingredients can be added singly or together. The mixing ratio of those ingredients does not matter in fact, but in general, each can be added by 0.016˜0.1 weight part per 100 weight part of the herbal extract of the present invention.
Advantageous Effect
The herbal extract of the present invention comprising Epimedium koreanum is very safe for human body because it is originated from the natural source, so that it can be used for the prevention and treatment of various influenza virus-induced diseases and alleviation of symptoms of those.
DESCRIPTION OF DRAWINGS
The application of the preferred embodiments of the present invention is best understood with reference to the accompanying drawings, wherein:
FIG. 1 is a graph illustrating the antiviral activity of Epimedium koreanum extract.
FIG. 2 is a graph illustrating the antiviral activity of Tamiflu.
DETAILED DESCRIPTION
Practical and presently preferred embodiments of the present invention are illustrative as shown in the following Examples.
However, it will be appreciated that those skilled in the art, on consideration of this disclosure, may make modifications and improvements within the spirit and scope of the present invention.
Example 1
Preparation of Epimedium koreanum Extract
Homegrown Epimedium koreanum was purchased and used as the test sample. One l of water was added to approximately 55 g of the selected Epimedium koreanum , which stood at room temperature for 1 hour. Then hot water extraction was performed at 100° C. for 3 hours, and as a result, approximately 100 ml of Epimedium koreanum extract was obtained. Approximately 4.7 g of freeze-dried material was obtained by freeze-drying the obtained Epimedium koreanum extract. The Epimedium koreanum extract or its freeze-dried material was used in this invention.
Example 2
Cytotoxicity Test
MDCK cells were distributed in a 96-well plate at the density of 1.5×10 5 cells/ml. Screening was performed when confluence reached 70-80%. The cells were washed with 1×PBS twice. The Epimedium koreanum extract prepared in Example 1 was diluted at different concentrations of 3.7, 1.23, 0.41, 0.14, and 0.05 mg/ml, which was added to each well containing 100 μl of cell growth medium (MEM+10% FBS, 100 U/ml penicillin, and 0.1 mg/ml streptomycin). The cells were cultured in a 5% CO 2 incubator at 37° C. for 48 hours. Then, MTT assay was performed to investigate cytotoxicity. For the positive control, Tamiflu was used at the concentrations of 1.23, 0.41, and 0.14 mg/ml.
As a result, the Epimedium koreanum extract showed cytotoxicity at the high concentration of 3.7 mg/ml, but did not show cytotoxicity at the concentration under 1.23 mg/ml. In the meantime, Tamiflu used as the positive control showed high cytotoxicity at the concentration of 1.23 mg/ml, and also demonstrated comparatively high cytotoxicity at the concentrations of 0.41 and 0.14 mg/ml as well, compared with the Epimedium koreanum extract (Table 1). Therefore, antiviral activity against influenza virus of the extract of the present invention was compared with that of the control at the concentrations of 1.23 mg/ml, 0.41 mg/ml, and 0.14 mg/ml, respectively.
TABLE 1
Cell viability (%)
Concentration of
3.7
1.23
0.41
0.14
0.05
treated sample
mg/ml
mg/ml
mg/ml
mg/ml
mg/ml
Virus growth
100
100
100
100
100
medium
(negative control)
Epimedium koreanum
75.4
78.2
89.9
94.7
96
extract
Positive control
—
20.83
54.94
64.02
—
Example 3
Antiviral Activity Test
MDCK cells were distributed in a 96-well plate at the density of 1.5×10 5 cells/ml. Screening was performed when confluence reached 70-80%. The cells were washed with 1×PBS twice. Virus growth medium (MEM+0.3% BSA, 2 μg N-tosyl-L-phenylalanine chloromethyl ketone (TPCK) treated 1 μg/ml trypsin, 100 U/ml penicillin, and 0.1 mg/ml streptomycin) was added to each well, followed by culture in a 5% CO 2 incubator at 37° C. for 15 minutes. The cells were inoculated with 100 TCID 50 of each H1N1 and H5N1, and 10 TCID 50 of H3N2, followed by culture in a 5% CO 2 incubator at 37° C. for 2 hours. 100 μl of virus growth medium containing Epimedium koreanum extract at the concentration of 1.23 mg/ml, 0.41 mg/ml, or 0.14 mg/ml was added thereto, followed by culture in a 5% CO 2 incubator at 37° C. for 48 hours. MTT assay was performed to investigate the antiviral activity of the Epimedium koreanum extract. For the positive control, Tamiflu was used at the concentrations of 1.23, 0.41, and 0.14 mg/d.
As a result, the Epimedium koreanum extract of the present invention demonstrated antiviral activity against PR8 H1N1 and H5N1 dose-dependently. The antiviral activity of the extract against Brisbane H1N1 was highest at comparatively low concentrations of 0.41 and 0.14 mg/ml. The extract also demonstrated antiviral activity against H3N2, and the activity at three different concentrations was all similar ( FIG. 1 ). On the contrary, Tamiflu used as the positive control demonstrated no antiviral activity at the concentration of 1.23 mg/ml, because of strong cytotoxicity ( FIG. 2 ).
Example 4
Acute Toxicity Test
Six weeks old specific pathogen-free (SPF) SD rats, provided from Daehan Biolink, Co., Ltd., Korea, were used for the following acute toxicity test. The Epimedium koreanum extract of Example 1 was orally administered once to 2 rats per group at the concentrations of 5 g/kg. Death, clinical symptoms, and weight changes in rats were observed, hematological tests and biochemical tests of blood were performed, and any abnormal signs in the gastrointestinal organs of chest and abdomen were checked with eyes during autopsy.
The results showed that the extract did not cause any specific clinical symptoms, weight change, or death in rats. No change was observed in hematological tests, biochemical tests of blood, and autopsy. The extract of the present invention is evaluated to be a safe substance since it does not cause any toxic change in rats up to the level of 5 g/kg and its estimated LD 50 value is much greater than 5 g/kg in rats.
Manufacturing Example 1
Preparation of Pharmaceutical Composition Containing Herbal Extract
<1-1> Preparation of Syrups
Syrups containing the herbal extract of the present invention by 2% (weight/volume) as an effective ingredient were prepared as follows. The herbal extract powder prepared in Example 1, saccharin, and sucrose were dissolved in 80 g of warm water. The mixture was cooled down, to which a mixture of glycerin, saccharin, flavors, ethanol, sorbic acid, and distilled water was added. Water was added to the mixture, making a total volume of 100 ml.
The constituents of the syrups are as follows.
Herbal extract 2 g Saccharin 0.8 g Sucrose 25.4 g Glycerin 8.0 g Flavor 0.04 g Ethanol 4.0 g Sorbic acid 0.4 g Distilled water Proper amount
<2-2> Preparation of Tablets
Tablets containing 15 mg of the herbal extract of the present invention as an active ingredient were prepared as follows.
250 g of the herbal extract prepared in Example 1, 175.9 g of lactose, 180 g of potato-starch, and 32 g of colloidal silicic acid were all mixed together. 10% gelatin solution was added to the mixture, which was then pulverized and filtered with 14-mesh sieve. The pulverized mixture was dried, to which 160 g of potato-starch, 50 g of talc, and 5 g of magnesium stearate were added to prepare tablets.
<1-3> Preparation of Injectable Solution
Injectable solutions containing 10 mg of the herbal extract of the present invention as an active ingredient were prepared as follows. 1 g of the herbal extract prepared in Example 1, 0.6 g of sodium chloride, and 0.1 g of ascorbic acid were dissolved in distilled water to make 100 ml of solution. The solution was put in a bottle and heated at 20° C. for 30 minutes for sterilization.
<1-4> Preparation of Powders
Powders were prepared by mixing 20 mg of the herbal extract prepared in Example 1, 100 mg of lactose, and 10 mg of talc, which were filled in airtight packs according to the conventional method for preparing powders.
<1-5> Preparation of Capsules
Capsules were prepared by mixing 10 mg of the herbal extract prepared in Example 1, 3 mg of crystalline cellulose, 14.8 mg of lactose, and 0.2 mg of magnesium stearate, which were filled in gelatin capsules according to the conventional method for preparing capsules.
Manufacturing Example 2
Preparation of Healthy Food
<2-1> Preparation of Food
Foods containing the herbal extract of the present invention were prepared as follows.
1. Preparation of Spices for Cooking
Health enhancing spices for cooking were prepared with 20˜95 wt % of the herbal extract of the present invention according to the conventional method.
2. Preparation of Tomato Ketchup and Sauce
Health enhancing tomato ketchup or sauce was prepared by mixing 0.2˜1.0 wt % of the herbal extract of the present invention with tomato ketchup or sauce according to the conventional method.
3. Preparation of Flour Foods
The herbal extract of the present invention was added to the flour by 0.5˜5.0 wt %. Health enhancing foods such as bread, cake, cookies, crackers and noodles were prepared with the flour mixture according to the conventional method.
4. Preparation of Soups and Gravies
The herbal extract of the present invention was added to soups and gravies by 0.1˜5.0 wt %. Health enhancing meat products, soups and gravies were prepared with this mixture by the conventional method.
5. Preparation of Ground Beef
Health enhancing ground beef was prepared by mixing 10 wt % of herbal extract of the present invention with ground beef according to the conventional method.
6. Preparation of Dairy Products
The herbal extract of the present invention was added to milk by 5˜10 wt %. Health enhancing dairy products such as butter and ice cream were prepared with the milk mixture according to the conventional method.
7. Preparation of Sun-Sik
Brown rice, barley, glutinous rice, and Yulmu (Job's tears) were gelatinized according to the conventional method, dried and pulverized to obtain 60-mesh powders. Black soybean, black sesame and wild sesame were steamed and dried according to the conventional method and pulverized to obtain 60-mesh powders. The herbal extract of the present invention was concentrated under reduced pressure, spray-dried and pulverized to obtain 60-mesh dry powders. Sun-Sik was prepared by mixing the dry powders of the grains, seeds and the herbal extract of the present invention according to the below ratio.
Grains (brown rice: 30 wt %, Yulmu: 15 wt %, barley: 20 wt %),
Seeds (wild sesame: 7 wt %, black soybean: 8 wt %, black sesame: 7 wt %),
Dry powders of the herbal extract (3 wt %),
Ganoderma lucidum (0.5 wt %),
Rehmannia glutinosa (0.5 wt %)
<2-2> Preparation of Beverages
1. Preparation of Carbonated Beverages
Syrup was prepared by mixing the herbal extract of the present invention with sugar (5-10%), citric acid (0.05-0.3%), caramel (0.005-0.02%), vitamin C (0.1-1%), and purified water (79-94%). The syrup was sterilized at 85-98° C. for 20-180 seconds, and then mixed with cooling water at the ratio of 1:4. Carbon dioxide was injected thereto by 0.5-0.82% to prepare carbonated beverages containing the herbal extract of the present invention.
2. Preparation of Health Beverages
The herbal extract of the present invention was mixed with liquid fructose (0.5 wt %), oligosaccharide (2 wt %), sugar (2 wt %), salt (0.5 wt %), and water (75 wt %). After mixing completely, the mixture was sterilized instantly and filled small containers such as glass bottles, pet bottles, etc, to prepare health beverages.
3. Preparation of Vegetable Juice
Health enhancing vegetable juice was prepared by adding 5 g of the herbal extract of the present invention to 1,000 ml of tomato or carrot juice according to the conventional method.
4. Preparation of Fruit Juice
Health enhancing fruit juice was prepared by adding 1 g of the herbal extract of the present invention to 1,000 ml of apple or grape juice according to the conventional method.
Those skilled in the art will appreciate that the conceptions and specific embodiments disclosed in the foregoing description may be readily utilized as a basis for modifying or designing other embodiments for carrying out the same purposes of the present invention. Those skilled in the art will also appreciate that such equivalent embodiments do not depart from the spirit and scope of the invention as set forth in the appended claims. | The present invention relates to herbal medicine extracts useful in the prevention or treatment of diseases caused by influenza viruses, and to a pharmaceutical composition or health food comprising the extracts. The herbal medicine extracts of the present invention are derived from natural materials, and are safe for the human body, and can be used in preventing and treating and in relieving symptoms of diseases caused by various types of influenza viruses. | 0 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to badges, name tags, advertising buttons and the like that can be pinned to the outside of a garment, and particularly to such badges and the like having a self-contained source of illumination.
[0002] It is known to provide a badge with a self-contained source of illumination to back-light a display surface bearing indicia. See, for example, U.S. Pat. No. 5,755,506 to Ray et al. Illuminated badges commonly include a lamp of the light-emitting diode (LED) or incandescent type, a battery, and an electrical switch and circuit to control the flow of current between the battery and the lamp.
SUMMARY OF THE INVENTION
[0003] The present invention provides an illuminated badge including a display panel having fluorescent pigment illuminated by an ultraviolet (UV) LED. The badge includes an electrical power source and an electrical switch for selectively controlling the flow of electrical current between the power source and the UV LED.
[0004] Other aspects of the present invention will be apparent from the following description of preferred embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] [0005]FIG. 1 is a front view of one embodiment of an ultraviolet illuminated badge with a display panel having fluorescent pigment.
[0006] [0006]FIG. 2 is a cross-sectional view of the badge of FIG. 1, taken in the plane 2 - 2 of FIG. 1 and viewed in the direction of the arrows.
[0007] [0007]FIG. 3 is a back view of the badge of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0008] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
[0009] Referring to FIGS. 1 - 3 , one embodiment of the present invention is a lighted badge 10 that includes a frame 12 , a display panel 14 , and an edge-lighting circuit mounted on a printed circuit (pc) board 16 . The pc board is affixed to the back of the display panel and has a pin 17 mounted thereon for pinning the badge to a garment. The edge-lighting circuit may include a plurality of ultraviolet (UV) LEDs 18 , a plurality of AG3, AG10 or other suitable button cells 20 , and an on-off switch 22 along with associated components including current-limiting resistors for the LEDS. Alternatively, pin 17 itself may be connected electrically so as to serve as the on-off switch if desired. The LEDs may be energized under control of an integrated circuit (IC) such that alternate actuation of the on-off switch causes the LEDs to turn on and off. Display panel 14 is preferably transparent or translucent plastic. Frame 12 may also be made of plastic and may be opaque, translucent or transparent.
[0010] Display panel 14 is illuminated by the UV LEDs in an edge-lighted manner such that ultraviolet light entering the edge of the display panel is transmitted and guided throughout the plastic material of the display panel, which preferably has fluorescent pigment mixed therein prior to molding. In an alternative configuration that may be desirable for some applications, fluorescent pigment may be applied as a coating to the back or front surfaces of the display panel. The ultraviolet light excites the fluorescent pigment and causes the display panel to glow, creating a novel and pleasing aesthetic effect, and also back-lighting any indicia, design or graphics that may be on the display panel.
[0011] As one example set of suitable dimensions, the fully assembled badge of FIGS. 1 - 3 may have an overall height of about 40 mm and an overall width of about 50 mm, and the exposed front surface of the display panel may have a height of about 25 mm and a width of about 40 mm. It will be understood that display badges of other sizes and proportions are also contemplated.
[0012] UV LEDs 18 emit light having a wavelength in the range of about 390 to about 410 nm, more preferably having a peak of about 390 nm to about 410 nm, and most preferably having a peak of about 400 nm. A suitable UV LED is the DL50PLDW503 UV LED available from Shue Kwong Optic Electronic Company, Shenzhen, China. The ultraviolet light is collected by an edge of display panel 14 and transmitted throughout the plastic material of the panel. The plastic material of display panel 14 may be a polycarbonate material that is mixed with fluorescent pigment and injection molded into the shape of a planar sheet with rabbeted edges for receiving the frame such that the display panel is substantially flush with the front surface of the frame. Alternatively, the plastic material may be polystyrene, PVC, ABS or acrylic materials. The pigment may be mixed at a ratio of about 1 to 2 grams of pigment per kilogram of plastic material. The fluorescent pigment may be a pigment that is commercially available from Wen Lee Plastic Pigment Company, Tungguong, China, such as Part No. 61113 (green), Part No. 31461 (blue), Part No. 238 (red), or Part No. 2600 (yellow).
[0013] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. For example, it is also contemplated that fluorescein dye may be mixed with ink to be applied to the display panel to form a logo or other indicia desired to be illuminated. | An illuminated display badge includes a frame surrounding a display panel that has fluorescent pigment illuminated by a UV LED. The badge includes an electrical power source such as a button cell and an electrical switch for selectively controlling the flow of electrical current between the power source and the LED. The fluorescent pigment emits visible light in response to being illuminated by ultraviolet light. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a process for the production of selectively hydrogenated polymers of conjugated dienes and more particularly to such a process utilizing a titanium hydrogenation catalyst.
The hydrogenation or selective hydrogenation of conjugated diene polymers has been accomplished using any of the several hydrogenation processes known in the prior art. For example the hydrogenation has been accomplished using methods such as those taught, for example, in U.S. Pat. Nos. 3,494,942; 3,634,594; 3,670,054; 3,700,633 and Re. 27,145, the disclosure of which patents are incorporated herein by reference. These methods known in the prior art for hydrogenating polymers containing ethylenic unsaturation and for hydrogenating or selectively hydrogenating polymers containing aromatic and ethylenic unsaturation, involve the use of a suitable catalyst, particularly a catalyst or catalyst precursor comprising a Group VIII metal.
In the methods described in the foregoing patents, a catalyst is prepared by combining a Group VIII metal, particularly nickel or cobalt, compound with a suitable reducing agent such as an aluminum alkyl. Also, while aluminum alkyls are the preferred reducing agents, it is known in the prior art that alkyls and hydrides of metals of Groups I-A, II-A and III-B of the Periodic Table of the Elements are effective reducing agents, particularly lithium, magnesium and aluminum. In general, the Group VIII metal compound is combined with Group I-A, II-A or III-B metal alkyl or hydride at a concentration sufficient to provide Group I-A, II-A and/or III-B metal to Group VIII metal ratios within the range from about 0.1:1 to about 20:1, preferably from about 1:1 to about 10:1. As indicated in the foregoing patents, the hydrogenation catalyst is generally prepared by combining the Group VIII metal compound and the reducing agent in a suitable solvent or diluent at a temperature within the range from about 20° C. to about 60° C. before the catalyst is fed to the hydrogenation reactor.
In 1985, Kishimoto et al. disclosed (in U.S. Pat. No. 4,501,857) that selective hydrogenation of the unsaturated double bonds in conjugated diolefin polymers could be achieved by hydrogenating such polymers in the presence of at least one bis(cyclopentadienyl)titanium (+4) compound and at least one hydrocarbon lithium compound wherein the hydrocarbon lithium compound can be an added compound or a living polymer having a lithium atom in the polymer chain. European patent application 0,339,986 discloses that this can be accomplished with the same titanium (+4) compounds in combination with an alkoxy lithium compound which can either be added directly or as a reaction mixture of an organo lithium compound with an alcoholic or phenolic compound. The use of these catalyst systems was said to be advantageous because the catalysts were said to be highly active so that they were effective even in such a small amount as not to affect adversely the stability of a hydrogenated polymer and require no deashing step. Further, the hydrogenation was said to be able to be carried out under mild conditions.
In U.S. Pat. No. 4,673,714, bis(cyclopentadienyl)titanium (+4) compounds were disclosed which preferentially hydrogenate the unsaturated double bonds of conjugated diolefins but do not require the use of an alkyl lithium compound. These titanium (+4) compounds were bis(cyclopentadienyl)titanium (+4) diaryl compounds. The elimination of the need for the hydrocarbon lithium compound was said to be a significant advantage of the invention disclosed in the '714 patent.
SUMMARY OF THE INVENTION
The present invention provides a catalyst and a process for the hydrogenation of conjugated diolefin polymers, especially copolymers thereof with alkenyl aromatic hydrocarbons, which first involves the polymerization or copolymerization of such monomers with an organo alkali metal polymerization initiator in a suitable solvent thereby creating a living polymer. The living polymer is preferably terminated by the addition of hydrogen. Finally, selective hydrogenation of the unsaturated double bonds in the conjugated diolefin units of the terminated polymer is carried out in the presence of at least one bis(cyclopentadienyl) titanium (+3) compound of the formula:
(C.sub.5 R".sub.5).sub.2 Ti--R
wherein R is alkyl, aralkyl, allyl, aryl, alkoxy, halogen, silyl or amine and R" is hydrogen, alkyl, aralkyl, aryl or mixtures thereof. If the polymer is terminated with hydrogen, addition of an initiator (cocatalyst) is not required. If an alcohol is used for termination, then an initiator such as hydrocarbon alkali metal compound must be used to achieve good hydrogenation.
DETAILED DESCRIPTION OF THE INVENTION
As is well known, polymers containing both aromatic and ethylenic unsaturation can be prepared by copolymerizing one or more polyolefins, particularly a diolefin, by themselves or with one or more alkenyl aromatic hydrocarbon monomers. The copolymers may, of course, be random, tapered, block or a combination of these, as well as linear, star or radial.
As is well known, polymers containing ethylenic unsaturation or both aromatic and ethylenic unsaturation may be prepared using anionic initiators or polymerization catalysts. Such polymers may be prepared using bulk, solution or emulsion techniques. In any case, the polymer containing at least ethylenic unsaturation will, generally, be recovered as a solid such as a crumb, a powder, a pellet or the like. Polymers containing ethylenic unsaturation and polymers containing both aromatic and ethylenic unsaturation are, of course, available commercially from several suppliers.
In general, when solution anionic techniques are used, conjugated diolefin polymers and copolymers of conjugated diolefins and alkenyl aromatic hydrocarbons are prepared by contacting the monomer or monomers to be polymerized simultaneously or sequentially with an anionic polymerization initiator such as Group IA metals, their alkyls, amides, silanolates, napthalides, biphenyls and anthracenyl derivatives. It is preferred to use an organoalkali metal (such as lithium, sodium or potassium) compound in a suitable solvent at a temperature within the range from about -150° C. to about 300° C., preferably at a temperature within the range from about 0° C. to about 100° C. Particularly effective anionic polymerization initiators are organolithium compounds having the general formula:
R.sup.5 Li.sub.n
Wherein:
R 5 is an aliphatic, cycloaliphatic, aromatic or alkyl-substituted aromatic hydrocarbon radical having from 1 to about 20 carbon atoms; and n is an integer of 1 to 4.
Conjugated diolefins which may be polymerized anionically include those conjugated diolefins containing from 4 to about 12 carbon atoms such as 1,3-butadiene, isoprene, piperylene, methylpentadiene, phenylbutadiene, 3,4-dimethyl-1,3-hexadiene, 4,5-diethyl-1,3-octadiene and the like. Conjugated diolefins containing from 4 to about 8 carbon atoms are preferred for use in such polymers. Alkenyl aromatic hydrocarbons which may be copolymerized include vinyl aryl compounds such as styrene, various alkyl-substituted styrenes, alkoxy-substituted styrenes, 2-vinyl pyridine, 4-vinyl pyridine, vinyl naphthalene, alkyl-substituted vinyl naphthalenes and the like.
In general, any of the solvents known in the prior art to be useful in the preparation of such polymers may be used. Suitable solvents, then, include straight- and branched-chain hydrocarbons such as pentane, hexane, heptane, octane and the like, as well as, alkyl-substituted derivatives thereof; cycloaliphatic hydrocarbons such as cyclopentane, cyclohexane, cycloheptane and the like, as well as, alkyl-substituted derivatives thereof; aromatic and alkyl-substituted derivatives thereof; aromatic and alkyl-substituted aromatic hydrocarbons such as benzene, naphthalene, toluene, xylene and the like; hydrogenated aromatic hydrocarbons such as tetralin, decalin and the like; halogenated hydrocarbons, particularly halogenated aromatic hydrocarbons, such as chlorobenzene, chlorotoluene and the like; linear and cyclic ethers such as methyl ether, methyl ethyl ether, diethyl ether, tetrahydrofuran and the like.
Conjugated diolefin polymers and conjugated diolefin-alkenyl aromatic copolymers which may be used in the present invention include those copolymers described in U.S. Pat. Nos. 3,135,716; 3,150,209; 3,496,154; 3,498,960; 4,145,298 and 4,238,202, the disclosure of which patents are herein incorporated by reference. Conjugated diolefin-alkenyl aromatic hydrocarbon copolymers which may be used in this invention also include block copolymers such as those described in U.S. Pat. Nos. 3,231,635; 3,265,765 and 3,322,856, the disclosure of which patents are also incorporated herein by reference. In general, linear and branched block copolymers which may be used in the present invention include those which may be represented by the general formula:
A.sub.z --(B--A).sub.y --B.sub.x
Wherein:
A is a linear or branched polymeric block comprising predominantly monoalkenyl aromatic hydrocarbon monomer units;
B is a linear or branched polymeric block containing predominantly conjugated diolefin monomer units;
x and z are, independently, a number equal to 0 or 1;
y is a whole number ranging from 0 to about 15, and the sum of x+z+y≧2.
Polymers which may be treated in accordance with this invention also include coupled and radial block copolymers such as those described in U.S. Pat. Nos. 4,033,888; 4,077,893; 4,141,847; 4,391,949 and 4,444,953, the disclosure of which patents are also incorporated herein by reference. Coupled and radial block copolymers which may be treated in accordance with the present invention include those which may be represented by the general formula:
[B.sub.x --(A--B).sub.y --A.sub.z ].sub.n --C--P.sub.n'
Wherein:
A, B, x, y and z are as previously defined; n and n' are, independently, numbers from 1 to about 100 such that n+n'≧3;
C is the core of the coupled or radial polymer formed with a polyfunctional coupling agent; and
Each P is the same or a different polymer block or polymer segment having the general formula:
B'.sub.x' --(A'--B").sub.y' --A".sub.z'
Wherein:
A" is a polymer block containing predominantly monoalkenyl aromatic hydrocarbon monomer units;
B' is a polymer block containing predominantly conjugated diolefin monomer units;
A'--B" is a polymer block containing monoalkenyl aromatic hydrocarbon monomer units (A') and conjugated diolefin monomer units (B"), the A'--B" monomer units may be random, tapered or block and when A'--B" is block, the A' block may be the same or different from A" and B" may be the same or different from B';
x' and z' are, independently, numbers equal to 0 or 1; and
y' is a number from 0 to about 15, with the proviso that the sum of x'+y'+z≧1.
The radial polymers may, then, be symmetric or asymmetric.
In the production of all of the polymers described above, the polymerization is preferably terminated by utilizing hydrogen, deuterium or a compound which releases hydrogen upon decomposition but the conventional alcohol terminating agent may also be used. The living polymer, or more accurately, the living end of the polymer chain, is terminated by the addition of hydrogen thereto. The theoretical termination reaction is shown using an S--B--S block copolymer for exemplary purposes:
S--B--S.sup.- Li.sup.+ +H.sub.2 →S--B--SH+LiH
As shown above, it is theorized that lithium hydride is formed during the termination process. Formed in this manner, it is not a reactive polymerization initiator. It is inert to polymerization and does not interfere with the molecular weight control of the next polymerization batch as alcohol can.
It is usually advisable to contact and vigorously mix the gas with the polymerization solution at the end of the polymerization reaction. This contact and vigorous mixing can be effected by adding the hydrogen gas through spargers in a mixing vessel containing polymer solution. The time of contact should be at least about ten seconds and preferably about twenty minutes to allow sufficient contact time for the reaction to occur. This is dependent upon the efficiency of the gas contacting equipment, gas solubility, solution viscosity and temperature. Alternatively, a continuous system could be employed whereby hydrogen is pumped into a solution prior to going to a statically mixed plug flow reactor. Hydrogen could also be dissolved in an appropriate solvent and added to the polymer solution to be terminated. Another method would be to cause the hydrogen to be absorbed into an absorption bed and then cause the polymer solution to flow through the absorption bed. The hydrogen contact could also be carried out by adding a material which gives off hydrogen upon decomposition, i.e. diimide.
When this improvement is used, the problems of using alcohol, i.e. the formation of lithium alkoxides and excess alcohol impurities, are avoided. Furthermore, this process has been found to have significant advantage if the polymer made is to be hydrogenated. It has been found that if the hydrogen method is used, the bis(cyclopentadienyl) titanium (+3) metal hydrogenation catalysts may be used without the necessity of a hydrocarbon lithium or alkoxy lithium promoter, whether added with the catalyst or present in the living polymer. Conventional alcohol termination may be used but then a catalyst promoter is required. The promoters which may be used include hydrocarbon lithium compounds of general formula LiR 6 , where R 6 denotes an alkyl or aryl group of one to twenty carbon atoms. For example, methyl lithium, ethyl lithium, propyl lithium, butyl lithium, sec-butyllithium, hexyl lithium, phenyl lithium, benzyl lithium and the like, could be used as a promoter for the bis(cyclopentadienyl)titanium (+3) catalysts. Also, organic aluminum compounds, organic zinc compounds and organic magnesium compounds may be used.
As stated above, the hydrogenation step of the present process is carried out in the presence of a bis(cyclopentadienyl) titanium (+3) metal compound of the formula:
(C.sub.5 R".sub.5).sub.2 Ti--R (I)
where R" may be the same or different, and may be hydrogen, alkyl, aralkyl, or aryl, and R is alkyl, aralkyl, allyl, aryl, alkoxy, halogen, silyl or amine.
An example of a titanium (+3) allyl compound is the following wherein R in formula (I) is represented as: ##STR1## where R 1 may be the same or different and may be hydrogen, alkyl, aralkyl, aryl, alkoxy, halogen or silyl. The preferred allyl compound is the one in the above formulae where R 1 is hydrogen because it is relatively easy to prepare.
Many aralkyl compounds can be used to advantage in the present invention. One preferred class is compounds wherein R in formula (I) is represented by: ##STR2## where the definitions of R 2 and R 3 are the same as that of R 1 . The preferred compound of this type is benzhydryl wherein R 2 and R 3 are hydrogen.
Aryl compounds are also useful herein. A preferred class is represented by the following formula wherein R in formula (I) is represented by: ##STR3## where R 4 has the same definition as R 1 , R 2 and R 3 . The preferred compound of this class is mesityl (2,4,6-trimethylbenzene).
This process will selectively hydrogenate conjugated diolefins without hydrogenating alkenyl aromatic hydrocarbons to any degree. Hydrogenation percentages of greater than 50% are easily obtained but it has been found that in order to achieve hydrogenation percentages of greater than 95% as is often desired, the alkali metal (for example, lithium) to titanium (+3) ratio should be at least about 2:1 and preferably is from about 3 to 30 when no promoter is used. There has to be sufficient alkali metal to ensure quick and sufficient interaction between the two metals. A high viscosity (high molecular weight) polymer may require a higher ratio because of the lesser mobility of the metals in the polymer cement. If alkali metal hydride must be added to increase the ratio, it can be made in situ by adding an organo alkali metal compound and hydrogen to the polymer (i.e., sparge), either before or after termination of the polymerization.
In general, the hydrogenation is carried out in a suitable solvent at a temperature within the range of from about 0° to about 120° C., preferably about 70° to about 90° C., and at a hydrogen partial pressure within the range from about 1 psig to about 1200 psig, preferably from about 300 to about 800 psig. Catalyst concentrations within the range from about 0.01 mM(millimoles) per 100 grams of polymer to about 20 mM per 100 grams of polymer, preferably 0.2 to 0.5 mM catalyst per 100 grams of polymer, are generally used and contacting at hydrogenation conditions is generally continued for a period of time within the range from about 30 to about 360 minutes. Suitable solvents for hydrogenation include, among others, n-heptane, n-pentane, tetrahydrofuran, cyclohexane, toluene, hexane, diethyl ether and benzene. Because of the small amount of catalyst present in the polymer after hydrogenation, it is not necessary to separate the hydrogenation catalyst and catalyst residue from the polymer. However, if separation is desired, it may be carried out using methods well known in the prior art. The hydrogenation reactions may be carried out in a batch process, or a semi-continuous process or a continuous process.
The catalysts of the present invention are prepared by using methods well known in the prior art. Generally they are prepared by reacting a bis(cyclopentadienyl)titanium dihalide with either appropriate Grignard reagents or appropriate alkyl lithium salts. The catalysts are isolated and redissolved in solvents consistent with that of the hydrogenation process prior to the hydrogenation reaction.
EXAMPLES
Preparation of Bis(cyclopentadienyl)titanium (+3) allyl
Bis(cyclopentadienyl)titanium dichloride (5 grams) was dissolved in 200 mL of anhydrous toluene. The solution was kept at room temperature. To this was added dropwise 7.3 grams of Mg(C 3 H 5 )Br over 30 minutes. After 24 hours of stirring, the deep purple solution was filtered and the compound was isolated by vacuum removal of the solvent. For further purification, the purple solid remaining was recrystallized from anhydrous hexane. ESR (Electron Spin Resonance) analysis of the material showed a single species with g-value of 1.993, which is consistent with literature values for compounds of this type. Elemental analysis gave consistent experimental values for carbon, hydrogen and titanium when compared to calculated values. Therefore, the catalyst was pure and homogeneous in nature.
Preparation of Bis(cyclopentadienyl)titanium (+3) benzhydryl
Bis(cyclopentadienyl)titanium dichloride (6 grams) was dissolved in 200 mL of anhydrous toluene. The solution was cooled to 0° C. To this was added dropwise 12.6 grams of LiCH(C 6 H 5 ) 2 dissolved in 150 mL anhydrous ether, over a period of 30 minutes. The reaction pot was left to stir for 2 hours. The solution was then filtered to remove LiCl and the final product was isolated from the filtrate by vacuum removal of the solvent. ESR analysis of the compound showed a single species with g-value of 1.996, which is consistent with literature values for compounds of this type. Elemental analysis gave consistent experimental values for carbon, hydrogen, and titanium when compared to calculated values. Therefore, the catalyst was pure and homogeneous in nature.
Preparation of Bis(cyclopentadienyl)mesityl titanium (+3)
Bis(cyclopentadienyl)titanium dichloride (2.5 grams) was dissolved in 200 mL of anhydrous toluene. The solution was cooled to 0° C. To this was added dropwise over a 30 minute time period, 2.8 grams of LiC 6 H 3 (CH 3 ) 3 dissolved in 100 mL anhydrous ether. The reaction was left to stir for 2 hours. The solution was then filtered to remove LiCl and the final product was isolated from the filtrate by vacuum removal of the solvent. ESR analysis of the compound showed a single species with g-value of 1.996, which is consistent with literature values for compounds of this type. Elemental analysis gave consistent experimental values for carbon, hydrogen, and titanium when compared to calculated values. Therefore, the catalyst was pure and homogeneous in nature.
Methanol Terminated Polymer Solution
EXAMPLE 1
A 600 lb. batch of polystyrene-polybutadiene-polystyrene (S--B--S--Li+) block copolymer 50,000 molecular weight was made by anionic polymerization using sec-butyl lithium as the initiator, in a 150 gallon pressurized reactor. The polymerization took place in a mixture of cyclohexane and diethyl ether at 60° C. for 3 hours. At the end of the polymerization reaction, methanol was added to terminate the polymerization. The resulting polymer solution contained 20% by weight.
All hydrogenation runs were carried out under similar conditions unless otherwise noted. A typical hydrogenation run consisted of pressure transferring to a 4-liter reactor a 20% by weight polymer solution. The polymer solution was then diluted with cyclohexane to produce a solution containing 5% to 15% by weight polymer. The temperature of the reactor was maintained at 40° C. The polymer solution was then sparged with hydrogen gas for 20 minutes, during which time the pressure of hydrogen gas within the reactor reached 70 psig. The reactor was then vented. Sec-butyl lithium as a cocatalyst was added to the polymer solution and stirred for 10 minutes. At this point catalyst (titanium +3 based) was added to the reactor as a toluene or cyclohexane solution. After addition of the catalyst, the reactor was heated to 80° C. and pressurized to 500-700 psig with hydrogen gas. The reaction was allowed to run for 3 hours, during which time samples were drawn from the reactor and analyzed by proton NMR to determine percent conversion of olefin. Gel permeation chromatography was done on the final samples to determine molecular architecture. It was found that only the olefin segments of the polymer were hydrogenated and that the aromatic rings of the polystyrene blocks were totally unaffected by this process.
EXAMPLES 2-4
Hydrogenation of Methanol Terminated Polymer Solution With Titanium (+3) Based Catalysts
A polystyrene-polybutadiene-polystyrene type block copolymer of 50,000 molecular weight was prepared as in Example 1. The polymer solution was 5% by weight polymer. The polymer was hydrogenated following the procedure described previously, i.e. at 80° C. and 500 psig hydrogen, with approximately 3 mM (millimoles) of titanium (+3) per 100 g of polymer. Table 1 is a summation of the results of these hydrogenation runs. All three titanium (+3) catalysts sufficiently hydrogenated the olefin segment of the block copolymer.
TABLE 1__________________________________________________________________________ Ti mM per Li:Ti ratio (Li OlefinExample 100 g polymer added as Cocatalyst) Conversion__________________________________________________________________________2 (C.sub.5 H.sub.5).sub.2 Ti(C.sub.3 H.sub.5) 3.2 5:1 98%3 (C.sub.5 H.sub.5).sub.2 TiCH(C.sub.6 H.sub.5).sub.2 3.8 5:1 98%4 (C.sub.5 H.sub.5).sub.2 TiC.sub.6 H.sub.2 (CH.sub.3).sub.3 3.8 5:1 98%__________________________________________________________________________
EXAMPLES 5-10
Hydrogenation of Methanol Terminated Polymer With Varying Amounts of Catalyst
A polystyrene-polybutadiene-polystyrene block copolymer of 50,000 molecular weight was prepared as in Example 1. The polymer solution was 5% by weight polymer. The polymer was hydrogenated at 80° C. and 700 psig hydrogen with varying amounts of bis(cyclopentadienyl)titanium (+3) allyl, Cp 2 Ti(C 3 H 5 ) and in some cases varying amounts of cocatalyst.
______________________________________ Li:Ti ratio Ti mM per (Li added as OlefinExample 100 g polymer Cocatalyst) Conversion______________________________________5 3.2 3:1 98%6 1.1 3:1 98%7 0.7 14:1 98%8 0.4 5:1 99%9 0.2 10:1 87%10 0.4 -- 0%______________________________________
It is apparent from these results that with higher loadings of catalyst the hydrogenation proceeds very efficiently. When the catalyst loading reaches a low level, however, the effectiveness of the hydrogenation is hindered. Li:Ti ratios do not appear to have a major role in determining the extent of hydrogenation when using bis(cyclopentadienyl) titanium allyl catalyst. With addition of no cocatalyst to the methanol terminated polymer solution as in example 10, no hydrogenation occurs.
Hydrogen Terminated Polymer Solution
EXAMPLE 11
A 600 lb. batch of polystyrene-polybutadiene-polystyrene (S--B--S--Li+) block copolymer 50,000 molecular weight was made by anionic polymerization using sec-butyl lithium as the initiator in a 150 gallon pressure reactor. The polymerization took place in a mixture of cyclohexane and diethyl ether at 60° C. for 3 hours. At the end of the polymerization reaction, the reactor temperature was approximately 60° C. The reactor was sparged with hydrogen for approximately 15 minutes. A colorimeter was used to determine when the termination was complete since S--B--S--Li+ has a distinct orange color with an absorption maximum at 328 mμ. The solution will turn colorless when the living ends are terminated. The colorimeter reading still showed "color" after 15 minutes of sparge time. At that time, the sparge vent was closed and the reactor pressurized up to 80 psig with hydrogen. The temperature was raised to 67° C. to decrease viscosity and improve mass transfer. The solution was mixed for 20 more minutes. During that time, the colorimeter reading dropped to baseline which reflected a terminated polystyrene-polybutadiene-polystyrene (S--B--S) polymer. The resulting solution was 20% by weight as polymer.
EXAMPLE 12
Hydrogenation of Hydrogen Terminated Polymer Solution
A polystyrene-polybutadiene-polystyrene type block copolymer of 50,000 molecular weight was prepared as in Example 11. The 20% by weight polymer solution was diluted with cyclohexane to a 15% by weight polymer solution. No cocatslyst was added to the reactor. The polymer solution was sparged with hydrogen for 20 minutes. The contents of the reactor were heated to 80° C. Bis(cyclopentadienyl)titanium (+3) allyl dissolved in 50 ml toluene was added to the reactor. After catalyst addition, the reactor was pressurized with hydrogen gas to 700 psig. The hydrogenation was allowed to proceed for 3 hours. Table 2 compares the results of this run with those of a run performed under the same conditions with methanol terminated polymer solution in which sec-butyl lithium had been added as a cocatalyst (Example 9 from above) and shows that the H 2 termination helps achieve higher hydrogenation conversion.
TABLE 2__________________________________________________________________________ExampleTi mM per 100 g polymer Li:Ti ratio (Li added as Cocatalyst) Olefin Conversion__________________________________________________________________________12 0.2 0 98% 9 0.2 10:1 87%__________________________________________________________________________
EXAMPLES 13-15
Hydrogenation of Hydrogen Terminated Feed With the Addition of a Cocatalyst
A 15% by weight solution of a polystyrene-polybutadiene-polystyrene type block copolymer of 50,000 molecular weight was prepared as in Example 11. The polymer solution was heated to 40° C., pressurized with hydrogen gas to 70 psig and allowed to stir for 20 minutes. The reactor was depressurized and sec-butyl lithium was added and stirred into the polymer solution for 10 minutes. The contents of the reactor were then heated to 80° C. Bis(cyclopentadienyl)titanium (+3) allyl, dissolved in toluene, was added to the reactor. After catalyst addition, the hydrogen pressure within the reactor was raised to 700 psig. The hydrogenation reactor proceeded for 3 hours. Table 3 summarizes the results of these runs. It is apparent that the addition of sec-butyl lithium to polymer solution that has been terminated with hydrogen gas hinders the extent of hydrogenation the polymer undergoes because Examples 13-15, where a promoter was used, produced less olefin conversion than Example 12 where no promoter was used.
TABLE 3______________________________________ Li:Ti ratio Ti mM per (Li added as OlefinExample 100 g polymer Cocatalyst) Conversion______________________________________13 0.2 5:1 58%14 0.2 10:1 34%15 0.1 20:1 20%12 0.2 0 98%______________________________________
EXAMPLES 16-19
Hydrogenation of Hydrogen Terminated Polymer
A 20% by weight solution of polystyrene-polybutadiene-polystyrene type block copolymer of 50,000 molecular weight was prepared as in Example 11. The polymer was hydrogenated as in Example 11. Table 4 highlights the results of these runs and expresses the consistent nature of the hydrogenation catalyst with a different polymer.
TABLE 4______________________________________ Ti mM per OlefinExample 100 g polymer No Addition of Li Conversion______________________________________16 0.2 0 97%17 0.2 0 98%18 0.2 0 98%19 0.2 0 97%______________________________________ | This invention provides a catalyst and a process for the hydrogenation of conjugated diolefin polymers which first involves the polymerization or copolymerization of such monomers with an organo alkali metal polymerization initiator in a suitable solvent thereby creating a living polymer. The living polymer is preferably terminated by the addition of hydrogen. Finally, selective hydrogenation of the unsaturated double bonds in the conjugated diolefin units of the terminated polymer is carried out in the presence of at least one bis(cyclopentadienyl)titanium (+3) compound of the formula:
(C.sub.5 R".sub.5).sub.2 --Ti--R
where R is selected from the group consisting of alkyl, aralkyl, allyl, aryl, alkoxy, halogen, silyl or amine and R", which may be the same or different, is selected from the group consisting of hydrogen, alkyl, aralkyl or aryl. | 2 |
This application is a national phase of PCT Application No. PCT/US2011/024881, filed Feb. 15, 2011, which in turn claims priority to U.S. Provisional Application No. 61/304,747, filed Feb. 15, 2010, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of connectors, more specifically to connectors suitable for high data rates.
2. Description of Related Art
Connectors suitable for relatively high data rates (greater than 10 Gbps) are known. For example, upcoming standards for high-data rate connectors offer 10 Gbps per channel and some include 12 two-way channels. In order to be compatible with optical channel data rates, however, there is increasing interest in being able to offer 25 Gbps capable connectors.
One issue that has been observed is a tendency for energy on the ground structure in a connector to resonate as the signaling frequency increases such that the wave length of the signaling frequency approaches the electrical length of the terminals in the connector. For stacked connectors, it is difficult to shorten the terminals and therefore, as signaling frequencies of 10+ GHz, there tends to be substantial resonance in frequencies. It has been determined that for connector systems with terminals on a board mounted connector and a circuit card in a mating plug connector, it is possible to damped the resonance and reduce the resultant noise by employing a circuit card as illustrated in FIG. 1 . As can be appreciated, two adjacent ground traces are coupled via a resistor to a median ground trace. The two adjacent ground traces and the median ground trace extend a distance until they are commoned together at an opposite end of the circuit card. More regarding this is construction and functionality is disclosed in International Patent Application No. PCT/US09/051409, which is incorporated herein by reference in its entirety. It has been determined that while such a design is effective, it tends to be difficult to package in certain applications. Therefore, certain individuals would appreciate a circuit card with additional improvements.
BRIEF SUMMARY OF THE INVENTION
A circuit card is provided that is suitable for use with high data rates and includes a resonance reduction circuit. In an embodiment, the circuit includes a meandering ground path so as to increase a time delay between a contact pad and a common ground area. In another embodiment the circuit includes a path with joined by an inductor and the inductor is configured to introduce additional time delay between the contact pad and a common area. By increasing the time delay between the contact pad and the common ground, resonance energy created by voltage potential between two distinct grounds terminals can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements and in which:
FIG. 1 illustrates a perspective view of an embodiment of a circuit card.
FIG. 2 illustrates a perspective view of an embodiment of a circuit card with a meandering ground path.
FIG. 3 illustrates an elevated plan view of the circuit card depicted in FIG. 2 .
FIG. 4 illustrates a perspective view of an embodiment of a circuit card with a coupled ground path.
FIG. 5 illustrates an elevated plan view of the circuit card depicted in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
The detailed description that follows describes exemplary embodiments and is not intended to be limited to the expressly disclosed combination(s). Therefore, unless otherwise noted, features disclosed herein may be combined together to form additional combinations that were not otherwise shown for purposes of brevity.
The embodiments below introduce a delay on the ground trace that extends between a resistor that couples a ground path to a median ground trace and a commoning bar. It has been determined that a distance between these points that provides an electrical length equal to a quarter wavelength of the frequency of interest will be sufficient to allow the resistor to be effective while shorter distances tend to cause the energy to “see” the short provided by the commoning bar rather than pass through the resistor. Therefore, the minimum length of a dampening circuit would generally be a distance that allowed the electrical length to be equal to a quarter wavelength of the frequency of interest.
As can be appreciated from FIG. 1 , circuit card 115 has a length 105 and includes a front edge 120 and a rear edge 124 . Contact pads 121 a can be used to receive signals while ground pads 121 b can be coupled to ground connectors in a corresponding mating connector. The signal contacts 121 a end in region 127 (with traces in another level 142 extending along the length 105 ) and a median ground trace 146 extends from there to commoning bar 118 . Thus, as depicted, on layer 143 there are adjacent ground traces 144 that are coupled to a median ground trace 146 near the region 127 by a resistor and the adjacent ground traces extend a distance that equates to a ¼ wave length before reaching a commoning bar 118 (and then terminating at ground pads 125 ).
For certain applications it is expected that such a circuit card length, while effective, would be longer than desirable based on other packaging constraints. The embodiments discussed below provide an alternative to the need for the longer ground trace (and corresponding circuit card).
FIGS. 2-3 illustrate features of an embodiment of a circuit card 200 with a surface 210 to support a first layer 220 that includes a plurality of ground traces configured to dampen resonant energy. While certain aspects of circuit card 200 are similar to the design of the circuit card depicted in FIG. 1 , the circuit card 200 includes a meandering path on the ground trace 232 a , 232 b , 232 c extending between resistors 240 and a commoning bar 221 . It should be noted that median ground trace 235 a , 235 b , however, does not meander although in another embodiment the median ground trace could meander. It has been determined that it is generally sufficient to increase the length of the ground traces 232 a , 232 b , 232 c such that they have an electrical length of about ¼ of the wavelength of interest. Thus, the depicted embodiment allows for shorter connectors while allowing ground pads 230 a , 230 b to be a standard size. However, as can be appreciated from the Figures, the electrical length between the resistors 240 and the commoning bar 221 can be increased by providing a meandering path.
Consequentially, while distance 205 is kept short for packaging and costs reasons, the distance the ground trace travels can be more than double the actual distance. Thus, the distance from the signal pads to rear edge 220 can be substantially shortened while still providing for a desired trace travel distance (which is expected to correlate to a resultant electrical length). This improvement allows for a reduction in the amount of material that is used, as well as allowing for smaller external packages. Signal pads 215 a , 215 b can thus be provided in a convention manner, or as otherwise desired, and can include front sections 216 to help improve the electrical performance of the circuit card 200 .
As can be appreciated, the meandering path is longer than the straight-line path. In an embodiment, the meandering path can be twice or even three times as long as a path that a corresponding straight-line section would provide. For example, in the embodiment depicted in FIGS. 2-3 , the straight-line distance 205 is about 1.65 mm and the distance of an equivalent meandering path is about 5.2 mm, which is more than three times the straight-line distance. Or to put it another way, the straight-line distance between the resistor and the commoning bar is about 3.3 mm while the distance via the meandering path is about 7.8 mm (or more than double the length between the resistor and the commoning bar). Consequentially, assuming the materials used to create the meandering path are such that the resultant electrical length increases proportionally, it is possible to more than double the electrical length between the resistor and the commoning bar. Thus, a trace with a meandering path offers significant potential for increased electrical length, which provides a greater time delay versus what would be available if a hypothetical straight-line trace were used.
FIGS. 4-5 illustrate another embodiment of a circuit card 300 . The circuit card 300 includes a surface 310 that supports a first layer 320 . In a manner similar to the embodiment depicted in FIGS. 2-3 , the first layer 320 includes signal pads 315 a , 315 b that are positioned between ground pads 330 a , 330 b , 330 c . The ground pads 330 a , 330 b , 330 c are connector to ground traces 332 a , 332 b , 332 c which are respectively connected to median ground traces 335 a , 335 b by resistors 340 . As depicted, the ground traces 332 a , 332 b , 332 c are split and are connected together with an inductor 350 a , 350 b , 350 c . Or to put it another way, the inductor bridges the split in the ground trace.
It has been determined that a inductor can introduce sufficient delay such that the energy passes through the resistor and is dampened rather than be reflected once energy reaches the commoning bar, even if the total length is less than ¼ wave length. Thus, the inductor can act to increase the electrical length of ground traces 332 a , 332 b , 332 c and the inductors can be configured so that the resultant physical length of the circuit card between the resistor and a commoning bar 312 can be substantially reduced to length required to mount the inductors and little more. In an embodiment, for example, the length of the inductor can be a substantial fraction of a distance 305 between the resistor and the commoning bar. Thus, the circuit card can be configured so that the resultant electrical length is more than double the electrical length if the trace just extended straight between the resistor 340 and the commoning bar 321 .
As can be appreciated, the use of an inductor allows for extremely short circuit card and this is beneficial when packaging constraints are significant. The meandering path, while potentially requiring a slightly longer circuit than might be needed with the inductor, still significantly reduces the required length compared to the straight trace version. Furthermore, the meandering trace design requires no additional components and therefore, depending on other requirements, may be less costly. It should be noted that in general the median ground trace can be shortened without concern for its electrical length as it has been determined that resonant dampening is not particularly sensitive to the length of the median ground trace. However, as can be appreciated, the ground trace can be configured so that the resultant electrical length of the ground trace is substantially greater than an electrical length of the median ground trace and in an embodiment it could be 50% greater, 100% greater (e.g., double) or more than 100% greater.
The disclosure provided herein describes features in terms of preferred and exemplary embodiments thereof. Numerous other embodiments, modifications and variations within the scope and spirit of the appended claims will occur to persons of ordinary skill in the art from a review of this disclosure. | A circuit card is provided that includes ground traces that extend from a resistor to a commoning bar, where a resultant electrical length between the resistor and the commoning bar and is configured to reduce energy carried on the ground terminals that could otherwise result in cross-talk. In an embodiment, the ground trace may be configured in a meandering manner. In another embodiment, the ground trace may be split and joined by an inductor. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of EP Application No. 07 006247.6, filed Mar. 27, 2007, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
The invention relates to a device for imprinting a three-dimensional article, in particular a container and/or workpiece, according to the preamble of claim 1 .
PRIOR ART
Three-dimensional articles, such as for example plate-like workpieces from the field of the furniture industry, are increasingly being imprinted with various patterns which are desired by the customers, for example by means of an ink-jet printing device. Thus, for example, EP 1 726 443 A discloses a generic device for imprinting workpieces in the region of a narrow face, with which high-quality patterns can be produced. However, it has been found that the desired quality of the printed image cannot be achieved in some cases, for example in deformable or non-uniform workpieces.
PRESENTATION OF THE INVENTION
It is therefore the object of the invention to provide a device of the type mentioned at the outset that allows high-quality patterning of articles even in the case of deformable or non-uniform three-dimensional articles.
According to the invention, this object is achieved by a device for imprinting a three-dimensional article according to claim 1 . Particularly advantageous developments of the invention are disclosed in the dependent claims.
The invention is based on the finding that, in a device of the type mentioned at the outset, the quality of the pattern is substantially dependent on the distance between the printing means and the surface to be patterned of the article. For this purpose, the invention provides for the device further to have a positioning means which is configured to bring the surface to be imprinted of the three-dimensional article into a predetermined relative relationship to, in particular a predetermined distance from, the printing means. In this way, it is possible to ensure, even in the case of deformable or non-uniform three-dimensional articles, at all times an optimum distance between the printing means and the surface to be patterned of the article, thus allowing high-quality patterning to be achieved.
At the same time, this results in a simple operation and a simple design of the device according to the invention, as precise application of the article to be imprinted or positional detection by means of sensors or the like is not imperative.
Within the scope of the present invention, the positioning means can be configured in a broad range of ways. A development of the invention provides for the positioning means to have at least one stop element, thus allowing effective relative positioning to be achieved with a simple design. However, it should be noted that the present invention also allows for the use of positioning means which operate in a contactless manner and can operate, for example, magnetically or otherwise.
Alternatively or additionally, the positioning means has according to a development of the present invention at least one endlessly revolving or rotating stop element, in particular a guide belt or a stop roll. Stop elements of this type combine precise positioning with low-friction and prompt conveyance of the articles to be imprinted in the device.
In all of the configurations of the positioning means, it is preferable, within the context of the present invention according to a development, for the positioning means to be disposed, in relation to the relative movement between the printing means and the three-dimensional article to be imprinted, upstream of the printing means at least in certain portions. This allows the surface to be imprinted to be brought particularly effectively into the desired position relative to the printing means, thus producing a high print quality.
According to a development of the invention, the positioning means has at least two stop elements. This results in a particularly precise definition of the relative positioning between the surface to be imprinted and the printing means. It is in this regard particularly preferable for at least one stop element to be movable. Various advantages can be achieved in this way. On the one hand, the movability of at least one stop element allows the device to be adapted to different dimensions of the articles to be imprinted; on the other hand, the movability of at least one stop element can also be utilised to generate a contact force between the stop elements and the surfaces to be imprinted in order as a result to guide the articles in a particularly stable manner and further to improve the print quality.
Within the context of the present invention, the printing means can be configured in a broad range of ways and have, for example, also a plurality of printing units in order to imprint the respective article not only on one surface but rather on a plurality or, if appropriate, all of the surfaces. It is in this regard particularly preferable for at least one stop element to be associated with each printing unit, thus allowing the precise relative positioning according to the invention to be achieved for each printing unit, although the device according to the invention can also have printing units without a stop element.
It is in this regard particularly preferable for at least one printing unit to be movable, preferably synchronously with the at least one associated stop element. This allows the device to be adapted in a simple and precise manner to a broad range of dimensions and configurations of articles to be imprinted without an associated loss in print quality.
The device according to the invention is particularly suitable for imprinting containers. A corresponding method according to the invention forms the subject-matter of claim 8 . This method is distinguished in that the container is imprinted in a condition in which it is ready to receive contents, in particular workpieces. This gives rise primarily to two main advantages. Firstly, the imprinting of a container which is ready to be received allows the container to be imprinted at a very late moment in the value creation chain, so a large number of container preforms (for example cardboard blanks) does not have to be printed long in advance; on the contrary, a corresponding overprint is, for example, applied just before the containers are filled. In addition, the method according to the invention ensures that the applied pattern is not impaired (for example scratched) by subsequent processing steps for manufacturing the container (for example processes of folding a cardboard blank). Overall, the method according to the invention thus allows high-quality and variable imprinting (which can be adapted to changing container contents) of the containers.
A development of the method according to the invention provides for, prior to imprinting, the container to be filled with contents, in particular workpieces. This opens up quite new possibilities for individualising containers. It is thus, for example, possible to fill containers with respective contents in large-scale production and, if appropriate, to seal them from the outset and to retrieve the filled containers only once a corresponding customer order has been placed and to provide them with the pattern which is desired by the customer and shows, for example, the customer's logo, etc. This prevents any wastage of containers which in the past resulted from imprinted container preforms being preproduced in large volumes without a corresponding customer order having been placed or sufficiently specified. Overall, this allows extremely variable and customer-individualised imprinting of containers with low wastage while the imprinting quality remains high.
In addition, a development of the method according to the invention provides for, prior to imprinting, the surface to be imprinted of the container being deformed by the positioning means. This allows curved surfaces of the container to be brought, prior to imprinting, into a flat state which is particularly suitable for high-quality imprinting. This can be advantageous, for example, in containers filled with workpieces, as it has been found that the process of filling the container in some cases produces undesirable deformation of the container, which can impair the printing process.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic plan view of a device for imprinting containers according to an embodiment of the invention; and
FIG. 2 is a schematic sectional view of the device shown in FIG. 1 , the section being guided in FIG. 1 along line II-II.
FIG. 3 illustrates an overview of a method for imprinting a three-dimensional article in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will be described hereinafter in detail with reference to the accompanying drawings.
FIG. 1 is a schematic plan view and FIG. 2 a schematic sectional view of a device 1 for imprinting containers 2 . The container 2 is in the present embodiment a cardboard comprising a filling opening which is located on top and was folded beforehand out of a cardboard blank. It should however be noted that the present invention is also applicable to completely different types of containers and also to completely different types of three-dimensional articles such as, for example, plate or strip-like workpieces such as are used in the field of the furniture industry and can often be made of wood, wood materials, plastics materials, etc. or combinations thereof.
The device 1 has in the present embodiment a printing means 10 comprising two printing units 12 , 14 which are configured in the present embodiment as ink-jet print heads comprising a plurality of ink outlets. The printing units 12 , 14 are each connected to an ink supply container 16 via a feed line 18 , although the ink supply container 16 can obviously also be disposed directly on the print head 12 , 14 .
Furthermore, the printing units 12 , 14 are each connected to a printer controller 12 ′, 14 ′, wherein the present invention also provides for an individual, integrated printer controller which, if appropriate, can also control the device as a whole. It should also be borne in mind that the present invention also allows any other types of printing means to be used.
In addition, the device 1 comprises a conveyor means 20 in order to convey the articles 2 to be imprinted along the printing units 12 , 14 . In this regard, the conveyor means 20 is in the present embodiment configured as a belt conveyor comprising two conveyor belts 22 , although obviously use may also be made of any other conveyor means such as chain conveyors, carriage conveyors, air-cushion conveyors and the like.
In addition, it should be noted that the conveyor means can also be configured in such a way that, alternatively or additionally to conveyance of the article to be imprinted, the printing means is moved. The present invention may thus relate both to continuously operating machines and to stationary machines and also to combinations thereof such as, for example, machines which operate in a clocked manner.
Furthermore, the device 1 according to the invention comprises a positioning means 30 which in the present embodiment is formed by two lateral guide belts 32 , 34 . In this regard, the guide face of the guide belts 32 , 34 extends substantially perpendicularly to the plane of conveyance of the conveyor means 20 . Expressed more generally, the guide face of the guide belts 32 , 34 or general stop elements extends substantially parallel to a printing output face (for example a face comprising nozzle outlets) of the associated printing unit 12 or 14 .
The guide belts 32 , 34 are, as may be seen most clearly in FIG. 1 , formed by endlessly revolving belts 32 ′ which are respectively tensioned about two deflection rolls 32 ″ and are optionally guided therebetween via a guide rail. Alternatively or additionally to the guide belts 32 , 34 shown, the positioning means used can obviously also be other types of stop elements such as, for example, stop rolls, stop plates, stop bolts or the like.
The guide belts 32 , 34 are disposed, in relation to the direction of conveyance of the articles 2 to be imprinted, upstream of the printing units 12 , 14 . In this regard, the guide belts 32 , 34 can be adjusted in such a way that their guide face facing the articles 2 to be imprinted is at a predetermined (orthogonal) distance from the ink outlets in the print heads 12 , 14 .
Of the two guide belts 32 , 34 , in the present embodiment the guide belt 34 is movable, thus allowing the distance between the guide belts 32 , 34 to be varied in accordance with the respective width of the articles 2 to be imprinted. In this regard, the printing unit 14 is also movable in conjunction with or simultaneously to the guide belt 34 in order at all times to ensure the desired or optimum (orthogonal) distance between the ink outlets in the print head 14 and the surface 2 ′ to be imprinted of the respective article 2 .
Disposed at the upstream end of the guide belts 32 , 34 are, in addition, funnel-like run-in elements 24 which help to introduce the articles conveyed by the conveyor means 20 securely into the region between the guide belts 32 , 34 .
The operation of the conveyor means 20 and of the positioning means 30 is in the present embodiment controlled by a machine controller 4 , although the machine controller may, as indicated hereinbefore, optionally also be combined with the printer controller 12 ′, 14 ′ to form an integral control unit. In this regard, the speed of conveyance of the conveyor means 20 is advantageously adapted to the speed of conveyance of the guide belts 32 , 34 .
Disposed downstream of the printing units 12 , 14 are, in addition, in the present embodiment two drying means 40 which are configured to dry or to set as promptly as possible the ink applied to the respective articles 2 . Although the present invention allows for the use of any desired printing medium or any desired printing ink, it has proven advantageous, in particular in the case of containers 2 which are to be imprinted and are made of cardboard or the like, to use an oil-based ink. This prevents possible problems in the drying or setting of UV ink using a UV drying means, as it has been found that the ink penetrates deep into the cardboard material and then is no longer optimally accessible to a process of drying or setting by the UV rays.
The operation of the device 1 according to the invention is carried out, within an integrated customer dispatch system for example, as follows. In a preceding process, plate-like workpieces such as floor panels or the like are, for example, produced, packaged in cardboard containers 2 and stored temporarily. In this regard, the cardboard containers 2 are, for example, brought in advance into a container form by the folding of cardboard blanks.
As soon as a specific customer order has been placed and the manner in which the customer wishes the containers 2 to be patterned is known, the ordered number of containers 2 is supplied to the device 1 and introduced into the region between the guide belts 32 , 34 . In this regard, the device 1 upstream of the guide belts can, if appropriate, detect the width of the containers 2 to be imprinted and adjust the position of the guide belt 34 , together with the position of the printing unit 14 , to the appropriate width. When the containers 2 are conveyed into the region between the guide belts 32 , 34 , the lateral portions of the containers 2 , which as a result of the articles located in the container 2 often protrude laterally, are in the present embodiment deformed and brought into a precisely defined position relative to the nozzle outlets in the printing units 12 and 14 . Alternatively, it is possible, especially in the case of dimensionally stable articles such as workpieces, for the articles not to be deformed by the guide belts 32 , 34 but rather to be displaced into the desired relative position.
As soon as the container 2 has issued from the region between the guide belts 32 , 34 , the lateral faces 2 ′ of the container 2 are imprinted using the printing units 12 , 14 .
Subsequently, the containers 2 pass through the drying means 40 which are used to dry the ink applied by the printing units 12 , 14 , so the containers 2 filled with workpieces can immediately afterwards continue to be processed, for example can be welded into a transparent film. | The invention relates to a method for imprinting a three-dimensional article, in particular a container and/or workpiece, and comprises utilizing a printing means, in particular an ink-jet printing means, for imprinting a surface of the three-dimensional article, and a conveyor means for bringing about a relative movement between the printing means and the three-dimensional article to be imprinted. The method according to the invention is characterised in that it further utilizes a positioning means which is configured to bring the surface to be imprinted of the three-dimensional article into a predetermined relative relationship to, in particular a predetermined distance from, the printing means. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional patent application of its co-pending parent patent application, Ser. No. 792,513 filed Nov. 13, 1991, now U.S. Pat. 5,242,353, issued Sep. 7, 1993.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to physical exercise apparatus in general, to a biasing element for providing resistance to movement of the members of the physical exercise apparatus and to methods of making the biasing element.
2. Prior Art Statement
It is known to provide an exercising machine comprising a fixed support member and a movable lever arm pivotally disposed on the support member, a biasing means having a first end member attached to the support member and a second end member attached to the lever arm, wherein the biasing means such as a tension spring, selectively provides resistance to motion of the lever arm in the plane of motion, for instance, see U.S. Pat. No. 3,638,941 to Kulkens. It is also known to provide an exercising machine wherein the biasing means comprises elastic means such as aero shock cords, for instance, see the U.S. Pat. No. 4,072,309 to Wilson. It is also known to provide an exercising machine wherein the biasing means comprises elastic means such as weight straps, for instance, see the SOLOFLEX® brochure wherein said weight straps comprise elastomeric band means with end means molded thereon. It is also known to provide biasing means comprising elastic means similar to the weight straps as cited in the above brochure wherein the elastic means is a molded elastomeric slab with integrally molded ends as depicted in FIG. 7.
SUMMARY OF THE INVENTION
It is one feature of this invention to provide new elastic biasing means comprising at least one polymeric band means having end means within said polymeric band means.
It is another feature of this invention to provide new elastic biasing means wherein a polymeric band means is selected from elastomeric band means of differing tensile strength.
It is another feature of this invention to provide new elastic biasing means having containing means mounted on the elastomeric band approximately centrally located between the end means or separable end members disposed within said end means.
It is another feature of this invention to provide new elastic biasing means wherein said cross-sectional area of said polymeric band is in the shape of a regular polygon or the sector of a circle.
It is another feature of this invention to provide new elastic biasing means wherein the cross-sectional area of said polymeric band means is preselected from the modulus of the material selected.
It is another feature of this invention to provide new elastic biasing means wherein the end members are provided with flange means which is contiguous with at least one surface of said elastomeric band.
It is another feature of this invention to provide a novel method of assembling the biasing means of the instant invention wherein the end members are initially separate from the elastomeric band means and the containing means.
It is another feature of this invention to provide new elastic biasing means wherein the containing means comprises a tubular material selected from the group containing metals, thermoplastic, thermoset elastomers, woven or non-woven textiles.
It is another feature of this invention to provide new biasing means wherein said containing means is provided with reference characters indicating the relative strength, safety warnings, manufacturers identification or advertising markings.
Other objects, uses and advantages of this invention are apparent from a reading of this description which proceeds with reference to the accompanying drawings forming a part thereof and wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded isometric view of an exercising machine showing the various parts thereof including the elastomeric band means of the instant invention; the machine being shown in three parts as FIGS. 1A, 1B, and 1C.
FIG. 2 is a plan view of the biasing means of the instant invention.
FIG. 3 is a isometric view of the elastomeric band means of the instant invention in an oval configuration prior to assembly.
FIG. 4 is a isometric view of the end member of the instant invention.
FIG. 5 is a plan view of the containing means of the instant invention showing customer's name located thereon.
FIG. 6 is a plan view of one of the biasing means of the prior art.
FIG. 7 is a isometric view of another of the biasing means of the prior art.
FIG. 8 is a plan view of the elastomeric band means of the instant invention disposed upon an assembly pin for assembly of the containment means.
FIG. 9 is an isometric view of the biasing means of the instant invention showing one end member disposed on an assembly pin and a bight in the other end means of the elastomeric band means for insertion of another end member.
FIGS. 10-15 are views of various sections of the elastomeric band means which may be used for the instant invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, the exercising machine employing the biasing means of this invention is generally indicated by the reference numeral 40. A base portion generally indicated by reference numeral 41 comprising base means 3, lateral support means 4 and support foot means 2 is assembled using bolts 27, washers 30 and nuts 34. Upright support means 1 is similarly attached to support foot means 2 while bench means 6 is fitted to support foot means 2 and brace means 5 with removable pins means 18 and 20. An upper body exercise apparatus, generally indicated by reference numeral 42, comprises upper head means 7 with biasing support means 8 and arm lever means 9 mounted thereto with mounting pins 21 and 22 respectively and handlebar lever means 10 with handlebar means 11 attached thereto with bolts 27, washers 31 and nuts 33 fitted to upper head means 7 using handlebar lever pivot means 19 inserted through hole means 25 in pivot tube means 26 or opposite pivot tube means 24 welded to upper head means 7.
Upper body exercising apparatus 42 is slidably mounted upon upright support means 1 by inserting removable bolt means (not shown) through hole means 36 in upper head means 7 and through hole means 35 in upright support means 1. Handlebar grips 29 are fitted over the ends of handlebar means 11 and handles 32 on arm lever means 9. Foam grips 16 cover the ends of arm lever means 9 and foam pads 17 are fitted over fulcrum means 14 on leg lifting lever means 13 and lower head means 12.
Lower head means 12 is slidably disposed in slot means 46 between bench rails 47 and secured thereto with bench brace mounting pin 20 through holes (not shown) in bench rails 47 and hole means 55 in lower head means 12. Bracket means 44 is disposed on the under side of lower head means 12. Bracket means 48 including fulcrum mounting means 49 is disposed on the end of lower head means 12 opposite the end thereof which is slidably disposed within slot means 46. Leg lifting lever means 13 is rotatably mounted upon lower head means 12 with bolt 28 inserted through hole means 50 in bracket means 48 and hole means 52 in leg lifting frame pivot tube 51 and secured thereto with nut 34. Foam pads 17 are disposed on fulcrum means 14 inserted through fulcrum mounting means 49 and fulcrum means 14 on both ends of leg lifting lever means 13.
Biasing means 15 are mounted upon support pins 38 and lever pins 39 on either side of upper head means 7 wherein said biasing means 15 provide resistance to the movement of arm lever means 9 in a horizontal plane of motion indicated by reference arrow 37.
Biasing means 15 may alternately be fitted over handlebar lever means pins 43 and removable pin means 18 which has been inserted into pivot tube means 26 in upper head means 7 providing resistance to motion of handlebar lever means 10 in a vertical plane as indicated by the double ended reference arrow 53. Removable pin means 18 may also be placed in opposite pivot tube means 24 above handlebar lever pin means 43 with handlebar lever means 10 pivotably mounted in pivot tube 26 providing resistance to motion of handlebar lever means 10 in a downward vertical direction as well.
Similarly, biasing means 15 may alternately be placed within bracket means 44 on lower head means 12 and bracket means 45 on leg lifting lever means 13 securing same with biasing means mounting pins 23 providing resistance to motion of leg lifting lever in a vertical plane as indicated by reference arrow 54.
Referring now to FIG. 2 through 5, biasing means 15 comprises elastomeric band means 60 of FIG. 3, end member 70 of FIG. 4 and containing means 80 of FIG. 5. Elastomeric band means 15 is taken transverse the longitudinal axis of each leg 68 and may be of any desired cross sectional configuration as shown in FIGS. 10-15, whereas in FIG. 3 inside surface 61 opposes outside surface 62 and first side edge 63 opposes second side edge (not shown), defining thereby a generally rectangular cross section elastomeric band means 60. End member 70 comprises hub means 71, an outer portion consisting of flange means 72 and 73, pulley surface 74, mounting hole means 75, and web means 76. Containing means 80 comprises a tube of elastomeric material with inside surface 81, outside surface 82, first end 83 and second end 84. Containing means 80 may also be provided with labeling means 85 disposed on outside surface 82 in any manner known in the art.
Referring now to FIG. 8 and FIG. 9, biasing means 15 is assembled by placing one end member 70 within bight 65 of elastomeric means 60 wherein the portion of inside surface 61 disposed within bight 65 of elastomeric band means 60 abuts a portion of pulley surface 74, and wherein first side edge 63 and second side edge (not shown) are contained between and contiguous with flange means 72 and 73 of end member 70. The opposite bight 65 is then placed over an assembly pin 90 which has containing means 80 placed thereon, elastomeric band means 60 is elongated by pulling upon end member 70 while containing means 80 is slidably moved from the position on assembly pin 90 toward end member 70 such that first end 83 of containing means 80 is adjacent end member 70. Inside surface 81 of containing means 80 is therefore contiguous with outside surfaces 62 and side edges 63 thereby containing elastomeric band means 60 in an oval configuration as shown in FIG. 10 when removed from assembly pin 90. Finally, a second end member 70 is placed within the open bight 65 of partially assembled biasing means 15 to produce the fully assembled biasing means 15 of FIG. 2. Assembly pin 90 may be utilized as shown in FIG. 10 to move containing means 80 toward the first end member 70 such that the second end member 70 may be more readily placed in bight 65 and to move containing means 80 to the final central position of biasing means 15.
Alternately, each bight 65 of elastomeric band means 60 may be placed upon mounting pins 90 and elongated to facilitate placement of containing means 80 in the central portion between bights 65 and then end member 70 may be separately placed within each bight 65 to provide the fully assembled biasing means 15.
Separate biasing means 15 of the instant invention may be constructed in a similar manner wherein the cross-sectional area of elastomeric band means 60 may be varied to provide a different amount of resistance to motion. For instance, the thickness of elastomeric band means 60 of FIG. 3 between outside surface 62 and inside surface 61 may be approximately 0.184 inch to provide a biasing means 15 which produces a resistance to movement of approximately 30 pounds when extended to 150% of the original distance from centerline 66 to centerline 67 which represents essentially the mid range of extension of any of the lever means of exercising means 40. Similarly, elastomeric band means 60 of FIG. 3 with a thickness between outside surface 62 and inside surface 61 of 0.368 inch will provide resistance of approximately 60 pounds when biasing means 15 is extended to 150% of the original distance between centerline 66 and 67. Therefore, biasing means 15 of FIG. 2 may be constructed of differing resisting strengths by changing the thickness of elastomeric band means 60 to provide a complete set of biasing means 15 for exercise apparatus 40 of FIG. 1.
Similarly, biasing means 15 of differing resisting strengths may be provided by altering the cross-sectional shape where said elastomeric band means 60 is other than rectangular in cross-section. For instance, see FIGS. 10-15 wherein various crossectional configurations of elastomeric band means 60 are shown. End member 70 may then also be altered to conform to the peripheral surface contour of elastomeric band means 60 such that elastomeric band means 60 is contained within first and second flange means 72 and 73 respectively while inside surface 61 of elastomeric band means 60 is supported by pulley surface 74 of end member 70.
The resisting strengths of the various elastomeric band means 60 of the instant invention are determined from the modulus of elasticity of the material selected. A modulus of elasticity curve of the material to be used for the elastomeric band means is determined by subjecting a tensile slab of the material to extension while measuring the force required to extend the material as is well known in the art. For instance, the force required to extend the material of elastomeric band means 60 to a length which is 33.3% greater than the original length was 1.089 pounds for a slab of material 0.250 inches wide by 0.040 inches thick. This yields a force per unit area of 108.9 pounds per square inch (psi). Therefore, in order to develop thirty pounds of force in biasing means 15 at an extension of 50% between the centerlines 66 and 67 which represents a 33.33 percent length extension of the entire length of elastomeric band means 60, the total crossectional area of each leg 68 would be 0.1377 square inches. Similarly, to develop ninety pounds of force in biasing means 15, the total cross-sectional area would be 0.413 square inches. Where elastomeric band means 60 is rectangular in cross-section and the width between flange means 72 and 73 of end member 70 is 0.750 inches, the thickness of elastomeric band means 60 would be the aforementioned 0.184 inches to develop thirty pounds whereas the thickness for elastomeric band means 60 would be 0.551 inches to develop ninety pounds.
The biasing means 60 of the present invention overcomes the limitations of biasing means 92 of the prior art as shown in FIG. 6 which can readily rupture by a quickly propagating crack developing from any of the discontinuities present in the molding operation of the flat slab. For instance, the biasing means 92 of FIG. 6 is prone to such rupture at the recess shown by arrow 91 because the highest stress is concentrated at this location when the biasing means 92 of FIG. 6 is extended. This high stress is created because the end section 93 of biasing means 92 does not extend and hence all the elongation of biasing means 92 must take place between the points 94 and 95. In the instant invention, inside surface 61 of elastomeric band means 60 contained within the bights 65 of biasing means 15 contacts surface 74 of each end member 70 and therefore biasing means 15 is free to move thereon, hence the entire length of elastomeric band means 60 extends substantially equally since the cross-sectional area of each segment of elastomeric band means 60 is uniform throughout the entire length thereof. This unique combination of elastomeric band means 60, end member 70 and containment means 80 provide biasing means 15 free of stress concentrations present in the prior art biasing means.
The unique combination of elastomeric band means 60, end member 70 and containment means 80 further provide the user with an early warning of any impending failure as elastomeric band means 60 moves about end member 70 during each extension thereof. Since the cross-sectional area is constant throughout elastomeric band means 60, no undue stress concentrations are present but any small crack which may occur on the outer surface thereof, where the highest stress during extension occurs, due to age of the elastomeric means 60 will be visible upon simple inspection prior to use. The user can then replace biasing means 15 or the elastomeric band means 60 at a convenient time without fear of sudden rupture of biasing means 15 during exercise.
The biasing means 15 of the present invention further provides a margin of safety to the user as the full resisting force of the biasing means is developed near the mid point of extension of the biasing means 15 rather than at the lesser extension of the prior art biasing means. For instance, the biasing means 15 with a thickness of 0.184 inch develops approximately 13.5 Kg at an extension of 150% of the original distance between centerlines 66 and 67 while biasing means 110 of FIG. 7 labeled 15 Kg develops approximately 63.5 kg at the same extension. At full extension of the lever means of machine 40, the biasing means of FIG. 7 develops approximately 100 Kg whereas the biasing means 15 develops only 30 Kg. Since the user will usually extend the biasing means to 80 to 100% of the full extension of the lever means, the biasing means of the prior art could cause over exertion and possible injury to the user. The biasing means 15 of the instant invention is therefore a much safer biasing means for the casual user of the machine 40.
The biasing means 15 of the instant invention may be provided with reference characters disposed upon the outside surface 82 of containing means 80 indicating the relative strength of the biasing means 15 without units of measurement thereon as in the prior art biasing means of FIG. 6. The reference characters may be numeric, alphabetic, symbolic or a combination thereof. The user of the exercising device 40 can then select biasing means 15 as desired for the exercise to be performed based upon previous experience eliminating the transfer of heavy weights from a weight rack.
The containing means 80 may be constructed of a material selected from the group comprising metals, thermoplastic or thermoset elastomers, woven or non-woven textile fabrics. The containing means 80 may be extruded, molded, woven, cast or formed by any means known in the art. The outer surface 82 of containing means 80 may be provided with labeling means 85 disposed thereon in a manner well known in the art. For instance, the containing means 80 of the instant invention has labeling means 85 disposed on the outer surface 82 by pad printing. The labeling means 85 comprises the company name, country of origin and an effort reference character of the biasing means 15. The labeling means 85 may further include safety information as desired by the customer or supplier or as required by Governmental agencies.
While the forms and methods of this invention now preferred have been illustrated and described as required by the Patent Statute, it is to be understood that other forms and method steps can be utilized and still fall within the scope of the appended claims wherein each claim sets forth what is believed to be known in each claim prior to this invention in the portion of each claim that is disposed before the terms "the improvement" and sets forth what is believed to be new in each claim according to this invention in the portion of each claim that is disposed after the terms "the improvement" whereby it is believed that each claim sets forth a novel, useful and unobvious invention within the purview of the Patent Statute. | A biasing means for an exercising machine is provided where one end of the biasing means is removably disposed on a lever arm of the exercising machine and the opposite end of the biasing means is disposed on a fixed support member of the exercising machine. The biasing means provides resistance to the movement of the lever arm in the plane of motion wherein the biasing means comprises at least one elastomeric band and a containing means to provide a bight on the ends of the biasing means for disposing on the respective portions of the machine. The biasing means may also have end members of support means placed within the bights. The biasing means, the containing means and the end members or support means may be initially separate and separable such that in the event of damage to any one of said means it may readily be replaced with another such elastomeric band means. | 0 |
BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to linear guide units.
[0002] More particularly, it relates to a linear guide unit which has an elongated guide housing with a longitudinal axis and with walls which limit a guide hollow space and has free ends which limit at least an longitudinal opening of the guide hollow space, two guide rails provided in the guide hollow space each for displaceably guiding a wagon in direction of the longitudinal axis, a connection unit for connecting the wagons to a wagon arrangement, a connecting part extending through the longitudinal opening and connecting the wagons to an object to be guided in direction of the longitudinal axis, and a cover element arranged between movement tracks of the connection part and covering connection units of the guide housing located at its ends and also the longitudinal opening.
[0003] Such a linear guide unit is disclosed for example in the German patent document DE 197 38 988 A1. With this linear guide arrangement the cover element is held with a pulling stress on the connection units of the guide housing located at the ends. Thereby a sagging of the cover element must be prevented, since the wagon arrangement otherwise during its movement on the cover plate would slide at least over a part of its movement path, which would lead to an undesirable noise generation during the operation of the linear guide unit. It has been shown however in practice that setting of the cover element under the pulling stress represents an efficient measure against a sagging of the cover element only to a certain maximum length. For long linear guide units the cover element slides on the wagon arrangement.
SUMMARY OF THE INVENTION
[0004] Accordingly, it is an object of the present invention to provide a linear guide unit which is a further improvement of the existing linear guide units of this type.
[0005] More particularly, it is an object of the present invention to provide a linear guide unit which in the case of great structural lengths generates a low noise or no noise at all.
[0006] In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a linear guide unit in which before or/and after the wagon arrangement, at least one supporting unit is provided which is displaceable in direction of the longitudinal axis and supports the cover element relative to the guide housing, and/or a support element is provided on the connection unit and supports the cover element relative to the wagon arrangement.
[0007] By means of these support units, the non supported free path lengths of the cover element can be maintained so small, that a sagging of the cover element due to gravity between two neighboring support units, which can represent the danger of a sliding contact with the wagon arrangement, must not be feared anymore. As known from German patent document DE 197 38 988 A1, the cover element can be held with a pulling stress between the end connection units to further reduce this danger.
[0008] It is to be understood that the connection of the wagons by the connection unit to a wagon arrangement can be obtained also by a one-piece construction. For example the wagon arrangement can be produced from an aluminum extrusion profile with inserted plates of steel.
[0009] For further reduction of noise generation, in particular during movement of the supporting units along the cover element, at least one sliding element can be provided between the at least one supporting unit and the cover element. For example, the sliding element can be arranged on the supporting unit, wherein in addition felt can be used as cost-favorable material for the slide element.
[0010] The inventive supporting unit can be used for example with linear guide devices, whose drive device for movement of the wagon arrangement in direction of the longitudinal axis includes a rod unit which is a in driven alternating connection with the rod arrangement or is bringable into such a connection. For example the linear unit can be driven by a roll body thread drive with a threaded spindle as the rod unit. Alternatively, the linear unit can be a magnetic piston unit with a runner which is arranged reciprocatingly movable along a rod, wherein the rod is formed as a hollow tube in which a magnetic piston is displaceable under the action of pressure fluid, and the runner is connected with the piston by magnetic forces. As a further alternative, the linear unit can be formed as a linear module with a runner which is arranged reciprocatingly movable around a rod, wherein the rod is formed as a displacement rod of a linear motor driven by the runner.
[0011] In all embodiments the support unit can be connected with a support arrangement or formed of one piece with it, for supporting the rod unit relative to the guide housing. The support arrangement can be formed for example as in German patent document DE 100 02 849 A1, whose complete content is incorporated here by reference for completion of the disclosure of the present application.
[0012] In accordance with a further embodiment of the invention, the support unit can have a substantially T-shaped construction in a section which is perpendicular to the longitudinal axis. Thereby with a relatively low space consumption by means of the vertical web of the T-shape, a broad support for the cover element can be provided by the transverse web of the T-shape. When the free ends of the transverse web of the T-shape in addition engage in associated grooves of the cover element, preferably in a form-locking manner, then the cover element can be thereby secured not only against a gravity-related sagging.
[0013] With the engagement of the transverse web of the T-shape into the grooves of the cover element it is further possible to secure it against lateral displacements. Whereby an undesirable engagement with the connection parts of the wagon can be prevented. A lifting of the cover element can be stopped with this engagement. Therefore the inventive linear guide unit can be mounted for example also in an overhead position. For further noise reduction, sliding elements can be provided on the engaging surfaces on the free ends of the transverse web of the T-shape with the grooves of the cover element, for example with felt elements.
[0014] In accordance with a further embodiment of the present invention a linear guide unit has an elongated guide housing with a longitudinal axis and with walls which limit a guide hollow space and has ends which limit at least one longitudinal opening of the guide hollow space, at least one guide rail in the guide hollow space for displaceably guiding a wagon in direction of the longitudinal axis, connecting part extending through the longitudinal opening and connecting the wagon in direction of the longitudinal axis to an object to be guided, and a cover band which covers the movement path of the connecting part in direction of the longitudinal axis before or/and after the wagon.
[0015] In this linear unit the cover band can have a substantially U-shaped cross-section with the free legs of the U-shape which are for example notched or toothed. With this notched or toothed construction, the cover band obtains a higher stability that assists in preventing in particular a displacement of the cover band in the guide hollow space due to application of outer force. When the longitudinal grooves which receive the side edges of the cover band correspond to the geometry of the angle side edges, the above mentioned guiding stability can also be secured by the form-locking cooperation of the free ledges of the U-shape with the guide groove.
[0016] A further feature of the invention deals with a mounting of the cover band on the wagon. When the base part for mounting a free end of the cover band on the mounting unit which operates as a wagon and the holding part of the mounting unit are connected of one piece with one another, for example by an elastic web, the mounting of the cover part on the wagon is significantly simplified since the mounting part can not be lost and must not be handled in a special way.
[0017] In accordance with a further feature of the present invention, a stripping unit is provided on at least one of the end connection units of the guide element, for stripping dirt which is located in the cover band. The stripping unit can be provided with an inclined surface which is set as a blade against the surface of the cover band.
[0018] The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, 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 DRAWINGS
[0019] FIG. 1 is a perspective, partially sectioned view of a linear guide unit in accordance with the present invention;
[0020] FIG. 2 is an end view of the linear guide unit of FIG. 1 , as seen in direction of the arrow 2 in FIG. 1 ;
[0021] FIG. 3 is a view showing a detail A of FIG. 2 on an enlarged scale;
[0022] FIG. 4 is a perspective view of a U-shaped cover band of the inventive linear guide unit;
[0023] FIG. 5 is a view showing a partial section of the cover band of FIG. 4 in cooperation with a receiving guide groove;
[0024] FIG. 6 is a detailed view of the linear guide unit for illustration of mounting of the cover band on a wagon; and
[0025] FIG. 7 is a view showing a stripping element for cleaning the cover band of the inventive linear guide unit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] FIGS. 1 and 2 shows an inventive linear guide arrangement which is identified as a whole with reference numeral 10 . It includes a guide housing 12 with a bottom wall 14 and two side walls 16 provided on its free ends with upper edge flanges 18 which are oriented toward one another. Guide rails 20 are received in guide grooves 22 on the bottom wall 14 of the guide housing 12 . The base of the left guide rail 20 in FIG. 2 is laterally movably received in a longitudinal groove 22 to avoid double fits, as known for example from German patent document DE 197 28 988 A1.
[0027] The guide rails 20 are mounted on the bottom wall 14 by a not shown bolts with bolt heads arranged so that they sink in sunk openings of the rail head surface. A wagon 24 is rollingly guided on each guide rail 20 . The construction and the operation of the wagons 24 are known and therefore not described in detail.
[0028] The wagon 24 of the left side and the wagon 24 of the right side are connected by a connection yoke 26 that can be made of one piece with the main bodies of the wagons 24 . The connection yoke 26 receives a ball screw nut of a spindle drive with a fixed seat, whose thread spindle 28 extends in a longitudinal direction L of the linear guide unit 10 . The threaded spindle 28 is set in rotation by a not shown motor around its axis which extends parallel to the longitudinal direction L. Thereby with interposition of the thread nut the wagon arrangement 30 formed by the wagons 24 and the connecting yoke 26 can be reciprocatingly moved in a longitudinal direction L of the linear guide unit 10 .
[0029] A connecting part 32 is mounted on each wagon 24 . It extends outwardly through the longitudinal openings 34 of the guide housing 12 , which is limited by both edge flanges 18 . The connecting parts 32 serve for connection of objects to be guided by the linear guide unit 10 for example tools.
[0030] Some covering features are provided for protecting an inner space 36 which is surrounded by the guide housing 12 from penetration of dust, in particular particles. First of all, a cover profile 40 is mounted on the end connecting units 38 of the guide housing 12 preferably with a pulling force, to cover the longitudinal openings 34 between the movement paths of the connecting parts 32 . Secondly, cover bands 42 are mounted on the connecting parts 32 for covering the movement paths of the connecting parts 32 in the longitudinal direction L before or after them. The cover bands 42 are guided in longitudinal grooves 18 a and 40 a of the edge flanges 18 of the guide housing 12 and the cover profile 40 . Furthermore, the cover bands 42 in the region of the cover caps 38 slide around the not shown deviating rollers and are guided back through recesses 14 a in the bottom of the right housing 12 to each other end of the connecting part 32 .
[0031] The above described inventive linear guide unit 10 with the features specified above corresponds with its construction and operation to the known linear guide unit which is disclosed in German patent document DE 197 38 988 A1. In order to complete the description, in particular with respect to the description of details of the construction and operation, this German reference DE 197 38 988 A1 is here incorporated as a reference.
[0032] In accordance with the present invention before and/or after (in front of and/or behind of) the wagon arrangement 30 , supporting units 50 are provided for preventing a gravity-caused sagging of the cover profile 40 in long linear guide units 10 , in particular linear guide units with a length more than 1.8 m. The supports unit 50 are mounted in the shown embodiment on its support arrangements 52 which support the thread spindle 28 on the guide housing 12 . For this purpose the support arrangement 52 engage with the edge flanges 52 a in corresponding longitudinal grooves 14 b of the bottom wall 14 of the guide housing 12 .
[0033] The support arrangements 52 , with their substantial structural features and their functions, in particular concerning the “take off” and “pick up” by the wagon arrangement 30 , are formed as disclosed in the German patent document DE 100 02 849 A1, which for completion of the description of the present application is incorporated here as a reference.
[0034] As can be seen in particular from FIG. 2 , the support units 50 are mounted on the support arrangements 54 . The support units 40 are substantially T-shaped and have a transverse web 56 and a vertical web 68 . The vertical web 58 serves for mounting the support unit 50 on the support arrangement 52 , while the transverse web 56 serves for supporting the cover profile 40 . As can be seen in particular from FIG. 3 , felt slide elements 60 on the upper side 56 a of the transverse web 56 are received in receiving depressions 56 b which are in sliding contact with the cover profile 40 .
[0035] Thereby the cover profile 40 on the one hand prevents sagging due to gravity force and on the other hand prevents a noise generation by the relatively cost favorable material felt when the support unit 50 together with the wagon arrangement 30 move along the cover profile. Supplementary an inventive support unit 50 ′ can be also arranged on the wagon arrangement 30 , in particular the connection yoke 26 .
[0036] The transverse web 56 of the support unit 50 has free ends 56 c (only one shown in FIG. 3 ), and engages with the free ends into a longitudinal groove 40 b of the cover profile 40 . It is to be understood that in the region of the free end 56 c , sliding elements 60 can be provided for supporting the cover profile 40 against a gravity-caused sagging. In the embodiment shown in FIG. 3 , in the region of the free ends 56 a further felt sliding element 62 is received in a recess 56 d of the lower side 56 a of the transverse web 56 . It is in sliding and supporting contact with a counter surface 40 c of the longitudinal groove 40 a of the cover profile 40 .
[0037] Based on the above described construction, the support unit 40 can support the cover profile 40 from gravity-caused sagging not only in the orientation shown in the drawings, but also in an overhang orientation, or in other words with the downwardly facing longitudinal opening 34 . Finally, it is also possible to provide further sliding elements, that are not shown in the drawings, in the region of the lateral limiting surface 56 f of the transverse web 56 . They avert a danger of a lateral displacement of the cover profile 40 relative to the support unit 50 and thereby relative to the wagon arrangement 30 .
[0038] While felt is proposed as the material for sliding element 60 and 62 , it is believed to be understood that also other suitable materials can be used for forming the sliding elements, for example TEFLON.
[0039] Additionally, the lug 40 d serves for mounting of the cover profile 40 on the connection parts 38 . Furthermore, the box-shaped construction of the cover profile 40 with its hollow profile sections increases the strengths and thereby reduces the tendency for sagging of the cover profile 40 .
[0040] In accordance with the present invention instead of the cover band 42 which is substantially flat and showed in FIG. 1 , a U-shaped cover band 42 ′ can be used as shown in FIG. 4 . With the cover band 42 ′, the free webs 32 a ′ of the U-shape are notched or toothed to allow bending of the cover band 42 ′ around a transverse axis Q which extends in the band plane E and is perpendicular to the longitudinal direction A. The bending is required for example for deviating the cover band 42 ′ in the region of the connection caps 38 or, as will be explained herein below with reference to FIG. 6 , for mounting on the wagons 24 .
[0041] The U-shaped construction of the cover band 42 has the advantage in that it provides the increase of the stability of the cover band 42 ′, in particular an increase of its guiding stability in the longitudinal grooves 18 ′ a or 40 ′ a of the edge flanges 18 of the guide housing 12 and the cover profile 40 , as shown in FIG. 5 . In particular, with the corresponding construction of the longitudinal grooves 18 ′ a and 40 ′ a with a form-locking cooperation of these longitudinal grooves with the cover band 42 ′, the cover band will not be able to move out of the longitudinal grooves.
[0042] FIG. 6 shows a mounting unit 70 which is used for mounting of the cover bands 42 and 42 ′ on the wagon 24 . With the use of the mounting unit 70 , the base part 74 which is mounted by a screw bolt 72 on the wagon 24 is formed of one piece with the mounting or clamping part 78 via an elastic web 76 . The elastic web 76 serves as a protection from losing of the clamping part 78 and allows turning on the clamping part 78 from the base part 70 for facilitating the insertion of the cover band 42 into an intermediate space 80 formed between the base part 74 and the clamping part 78 . Preferably the free ends of the cover band 42 can be placed around a support part 82 . The support part 82 can cooperate in a form-locking manner with a bolt 84 which mounts the clamping part 78 on the base part 74 . This increases the clamping efficiency based on the placement of the cover band 42 around the support part 82 and facilitates the accompanying doubling of the clamping points. On the other hand, the support part 82 has an increased head 82 a which, with applying a pulling stress on the cover band 42 , additionally form-lockingly opposes a movement out of the gap 80 .
[0043] Finally, in the region of the connection cap 38 and in particular at the side identified in FIG. 1 with reference numeral 1 , a stripping element 90 is provided as shown in FIG. 7 . The stripping element 90 is set with an inclined face 92 against the surface of the cover band 42 and 42 ′ to strip dirt located on the cover band 42 . The stripping element 20 can be pre-stressed at the lower side which faces the cover band 42 and 42 ′, by a sealing element. The sealing element can be composed for example of felt and increases the stripping action of the inclined face 92 .
[0044] 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 constructions differing from the types described above.
[0045] While the invention has been illustrated and described as embodied in linear guide units, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
[0046] 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. | In a linear guide unit that has an elongated guide housing which limits a guide hollow space with a longitudinal opening, a wagon arrangement which is displaceably guided in the guide hollow space on guide rails, a connection part for connecting the wagon arrangement to an object to be guided, a cover element arranged between movement tracks of the connection part and covering the longitudinal opening, in accordance with the present invention forwardly of and/or rearwardly of the wagon arrangement, at least one support unit is arranged displaceably in direction of the longitudinal axis for supporting the cover element relative to the guide housing; also additionally or alternatively the support unit can support the cover element relative to the wagon arrangement. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present patent application is a continuation of the patent application identified by U.S. Ser. No. 13/669,006, filed Nov. 5, 2012 which claims the benefit of, and the priority to, U.S. Provisional Application No. 61/556,179, titled “System and Method f o r Increasing Security in Internet Transactions”, and filed on Nov. 5, 2011. The content of which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates generally to the processing of financial transactions conducted over the internet, and more particularly to a system and method for increasing security in internet transactions.
BACKGROUND
[0003] When consumers make purchases from internet retailers, they typically must enter their payment card information manually into a purchase form on an applicable web site. That payment card information is then sent to the consumer's bank to validate that the consumer has funds in their account to cover the merchandise being purchased. On the other hand, when the same consumer uses the same payment card to purchase at a physical retailer, they will typically swipe the card at a point-of-sale terminal. Although the same card is used in both instances, the payment networks (such as Visa, MasterCard, American Express, Discover, etc.) charge merchants a higher rate in the former scenario (generally referred to as a “Card Not Present” rate) and a lesser rate in the latter scenario (generally referred to as a “Card Present” rate).
[0004] One of the significant reasons for the difference between the two rates stems from the deviation in the trustworthiness of the payment card data being presented. For internet purchases, the consumer generally enters only the payment card information that is visible on the payment card itself (such as the 16 digit card number, the expiration date, and the CVV), along with certain other personally identifiable information (such as the user's name and mailing or billing address). However, when the consumer's card is swiped at a physical merchant, much more information, which is saved on the magnetic stripe or in the smart card chip of the plastic payment card, is sent to and verified by the consumer bank. Thus, the difference in the amount of information provided by the payment card affects the trustworthiness, and ultimately, the costs to the merchant, of the transactions.
[0005] Accordingly, there is a need for a system and method that can improve the level of trustworthiness for interne transactions, and thus potentially decrease the costs attributed to such transactions by payment networks.
SUMMARY
[0006] The following presents a simplified summary of the present disclosure in order to provide a basic understanding of some aspects of the disclosure. This summary is not an extensive overview of the disclosure. It is not intended to identify key or critical elements of the disclosure or to delineate the scope of the disclosure. The following summary merely presents some concepts of the disclosure in a simplified form as a prelude to the more detailed description provided below.
[0007] Methods, systems, apparatuses, and computer readable media are disclosed for increasing security of financial transactions conducted over the Internet.
[0008] In an example aspect, a user may be prompted for authorization to permit a pending purchase initiated by a purchase initiating device. A secure communication channel may be established with a server and a credential may be communicated via the secure communication channel. A token may be generated based on the credential and communicated to the server via a mobile network interface.
[0009] Aspects of the disclosure may be provided in at least one non-transitory computer readable medium having computer-executable instructions, that when executed by at least one processor, cause performance of one or more of the process steps described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a better understanding of the present disclosure, non-limiting and non-exhaustive embodiments are described in reference to the following drawings. In the drawings, like reference numerals refer to like parts through all the various figures unless otherwise specified.
[0011] FIG. 1 a is a block diagram illustrating some of the logical blocks within a portable communication device and the operable interconnections between an end user's communication device, an internet retailer server, and an issuance system that may be relevant to the present system.
[0012] FIG. 1 b illustrates one potential dialogue window that may be programmed for use in association with the present system when the user activates the “use e wallet” button in FIG. 1 a.
[0013] FIG. 2 is a flow diagram illustrating one exemplary process for processing internet transactions using information present in the secure element.
[0014] FIG. 3 is a flow diagram illustrating a second exemplary process for processing internet transactions using information present in the secure element.
DETAILED DESCRIPTION
[0015] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, specific exemplary embodiments by which the invention may be practiced. This invention may, however, be embodied 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 fully convey the scope of the invention to those skilled in the art. Among other things, the present invention may be embodied as methods or devices. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. The following detailed description is, therefore, not to be taken in a limiting sense.
[0016] The present invention provides a system and method that can be utilized with a variety of different portable communication devices, including but not limited to PDA's, cellular phones, smart phones, laptops, tablet computers, and other mobile devices that include cellular voice and data service as well as preferable access to consumer downloadable applications. One such portable communication device could be an iPhone, Motorola RAZR or DROID; however, the present invention is preferably platform and device independent. For example, the portable communication device technology platform may be Microsoft Windows Mobile, Microsoft Windows Phone 7, Palm OS, RIM Blackberry OS, Apple OS, Android OS, Symbian, Java or any other technology platform. For purposes of this disclosure, the present invention has been generally described in accordance with features and interfaces that are optimized for a smart phone utilizing a generalized platform, although one skilled in the art would understand that all such features and interfaces may also be used and adapted for any other platform and/or device.
[0017] The portable communication device may include one or more short proximity electromagnetic communication devices, such as an NFC, RFID, or Bluetooth transceiver. It is presently preferred to use an NFC baseband that is Compliant with NFC IP 1 standards (www.nfcforum.org), which provides standard functions like peer-to-peer data exchange, reader-writer mode (i.e., harvesting of information from RFID tags), and contactless card emulation (per the NFC IP 1 and ISO 14443 standards) when paired with a secure element on the portable communication device and presented in front of a “contactless payment reader” (see below at point of sale). As would be understood in the art by those having the present specification, figures, and claims before them, the NFC IP 1 standards are simply the presently preferred example, which could be exported—in whole or in part—for use in association with any other proximity communication standard. It is further preferred that the portable communication device include an NFC/RFID antenna (conformed to NFC IP 1 and ISO 14443 standards) to enable near field communications. However, as would be understood in the art NFC/RFID communications may be accomplished albeit over even shorter ranges and potential read problems.
[0018] The portable communication device also includes a mobile network interface to establish and manage wireless communications with a mobile network operator. The mobile network interface uses one or more communication protocols and technologies including, but not limited to, global system for mobile communication (GSM), 3G, 4G, code division multiple access (CDMA), time division multiple access (TDMA), user datagram protocol (UDP), transmission control protocol/Internet protocol (TCP/IP), SMS, general packet radio service (GPRS), WAP, ultra wide band (UWB), IEEE 802.16 Worldwide Interoperability for Microwave Access (WiMax), SIP/RTP, or any of a variety of other wireless communication protocols to communicate with the mobile network of a mobile network operator. Accordingly, the mobile network interface may include a transceiver, transceiving device, or network interface card (NIC). It is contemplated that the mobile network interface and short proximity electromagnetic communication device could share a transceiver or transceiving device, as would be understood in the art by those having the present specification, figures, and claims before them.
[0019] The portable communication device further includes a user interface that provides some means for the consumer to receive information as well as to input information or otherwise respond to the received information. As is presently understood (without intending to limit the present disclosure thereto) this user interface may include a microphone, an audio speaker, a haptic interface, a graphical display, and a keypad, keyboard, pointing device and/or touch screen. As would be understood in the art by those having the present specification, figures, and claims before them, the portable communication device may further include a location transceiver that can determine the physical coordinates of device on the surface of the Earth typically as a function of its latitude, longitude and altitude. This location transceiver preferably uses GPS technology, so it may be referred to herein as a GPS transceiver; however, it should be understood that the location transceiver can additionally (or alternatively) employ other gee-positioning mechanisms, including, but not limited to, triangulation, assisted GPS (AGPS), E OTD, CI, SAI, ETA, BSS or the like, to determine the physical location of the portable communication device on the surface of the Earth.
[0020] The portable communication device will also include a processor (e.g., microprocessor) and mass memory or other non-transitory computer readable medium. The mass memory may include ROM, RAM as well as one or more removable memory cards. The mass memory provides storage for computer readable instructions and other data, including a basic input/output system (“BIOS”) and an operating system for controlling the operation of the portable communication device. The computer readable instructions, when executed by the processor, may cause the portable communication device to perform the functions described herein attributed to the portable communication device. The portable communication device will also include a device identification memory dedicated to identify the device, such as a SIM card. As is generally understood, SIM cards contain the unique serial number of the device (ESN), an internationally unique number of the mobile user (IMSI), security authentication and ciphering information, temporary information related to the local network, a list of the services the user has access to and two passwords (PIN for usual use and PUK for unlocking). As would be understood by those in the art having the present specification, figures, and claims before them, other information may be maintained in the device identification memory depending upon the type of device, its primary network type, home mobile network operator, etc.
[0021] Each portable communication device may have two subsystems: (1) a “wireless subsystem” that enables communication and other data applications as has become commonplace with users of cellular telephones today, and (2) the “secure transactional subsystem” which may also be known as the “payment subsystem”. The secure transactional subsystem includes the secure element and associated device software for communication to management and provisioning systems as well as the customer facing interface for use and management of secure data stored in the secure element. It is contemplated that this secure transactional subsystem will preferably include a Secure Element, similar (if not identical) to that described as part of the Global Platform 2.1.X, 2.2, or 2.2.X (www.globalplatform.org). The secure element has been implemented as a specialized, separate physical memory used for industry common practice of storing payment card track data used with industry common point of sale; additionally, other secure credentials that can be stored in the secure element include employment badge credentials (enterprise access controls), hotel and other card-based access systems and transit credentials. An additional secure data store may also be available on the portable communication device.
[0022] Each of the portable communications devices is connected to at least one mobile network operator. The mobile network operator generally provides physical infrastructure that supports the wireless communication services, data applications and the secure transactional subsystem via a plurality of cell towers that communicate with a plurality of portable communication devices within each cell tower's associated cell. In turn, the cell towers may be in operable communication with the logical network of the mobile network operator, POTS, and the Internet to convey the communications and data within the mobile network operator's own logical network as well as to external networks including those of other mobile network operators. The mobile network operators generally provide support for one or more communication protocols and technologies including, but not limited to, global system for mobile communication (GSM), 3G, 4G, code division multiple access (CDMA), time division multiple access (TDMA), user datagram protocol (UDP), transmission control protocol/Internet protocol (TCP/IP), SMS, general packet radio service (GPRS), WAP, ultra wide band (UWB), IEEE 802.16 Worldwide Interoperability for Microwave Access (WiMax), SIP/RTP, or any of a variety of other wireless communication protocols to communicate with the portable communication devices.
[0023] Turning now to the figures, as shown in FIGS. 1 a and 1 b , each portable communication device 50 may contain a wallet 100 , payment libraries 110 , secure clement 120 , NFC Baseband 200 , an optional secure data store 115 , and diagnostics agent 170 . Wallet 100 is a computer application that allows the consumer to view and select credentials (e.g., one or more payment cards) stored in the device 50 in secure element 120 (or perhaps secure data store 115 ).
[0024] The payment libraries 110 are used by wallet 100 t o manage and perform housekeeping tasks on the secure element 120 and perform over-the-air (OTA) provisioning via data communication transceiver (including its SMS channel), on the device 50 . It is contemplated that the OTA data communications could be encrypted in some manner and an encryption key will be deployed on the device 50 .
[0025] The secure data store 115 provides secured storage on the portable communication device 50 . Various levels of security may be provided depending upon the nature of the data intended for storage in secure data store 115 . For instance, secure data store 115 may simply be password-protected at the operating system level of device 50 . As is known in these operating systems, the password may be a simple alphanumeric or hexadecimal code that is stored somewhere on the device 50 . Alternatively, the data in secure data store 115 is preferably encrypted. More likely, however, the secure data store 115 will be set up as a virtual secure element in the manner disclosed in the co-pending patent application (owned by the assignee of the present application) entitled “System and Method for Providing A Virtual Secure Element on a Portable Communication Device” filed on October 21, 2011 and hereby incorporated by reference.
[0026] FIG. 2 describes one exemplary process for enabling smart card-based card payment data from a portable communication device 50 to be used to complete a purchase from an internet retailer (either via a browser or an app operating on the communication device (which has a secure element 120 )). It should be understood by those skilled in the art having the present specifications and drawings before them that although the present process may be more streamlined when used in conjunction with a browser or an “app” operating on the portable communication device 50 (having a secure element 120 operably associated therewith), it is contemplated—particularly in view of the present invention—that secure elements may be deployed some day in the future in association with desktop, laptop and tablet computers. Moreover, there is described herein an embodiment that allows a transaction commenced on a computer without a secure element to be paid for using the secure element on a portable communication device. In some embodiments, the browser and/or apps may be granted permission to access the secure element directly or more preferably via the wallet 100 . In the depiction of FIGS. 1 a and 1 b , we have illustrated a consumer having accessed an online store via their internet browser deployed on a desktop computer.
[0027] Returning to FIG. 2 , in step 502 , a consumer adds one or more items that they wish to purchase to their online shopping basket, and then proceeds to a checkout screen, in step 504 , where the user provides an indication of their intent to purchase those items. In particular, FIG. 1 a illustrates the user having added an item (i.e., the book War and Peace by Leo Tolstoy) to the online shopping basket of that store. In step 506 , the system detects whether there is a secure element on the device in current communication with the online shopping basket/retailer. If a secure element is detected, the internet retailer server offers the consumer the option to pay with a card stored in the device's secure element in step 508 . Where the consumer has been shopping on an application or via a browser operating on a device that has a secure element 120 (such as portable communication device 50 ) the system may already be aware of the presence of the secure element so the checkout flow will automatically provide “use e wallet” as one option for payment (as depicted in FIG. 1 a ). Of course, checking for a secured element before the user chooses the e wallet transaction option would not be required. As such, the option to pay using a card stored in a secure element may simply be presented to all consumers, regardless of whether the device they are using contains a secure element. Of course, in the future when all communication devices contain secure elements this detection step would be unnecessary.
[0028] Where the user has been shopping on an application or via a browser operating on a device that does not have its own secure element, as illustrated in FIG. 1 b , upon selection of the “eWallet” button of FIG. 1 a , the user interface of the system prompts the consumer to provide unique identifying information of a device that does have a secure element. Provision of this or some other unique identification information (such as IMEI, MEJD, or PIN) to the system will be used to send a unique link (associated with the shopping cart and/or retailer's processing services) to the consumer's email address, phone number, an app operating on the uniquely identified device. This link, which will likely comprise a URL, would preferably be authenticated in association with the secure element 120 before the link was presented to the consumer. Once the link is presented, the user can then select the link on the identified communication device 50 to complete the transaction.
[0029] If, in step 510 , the consumer chooses to use a credit card whose information is stored in the secure element (i.e., a credential) as their method of payment, the system commands the secure element to generate a secure token and establish a secure data channel (step 512 ) between the secure element 120 in the communication device 50 to a payment processing service provider. The secure channel may be established in a similar, if not identical manner that is typically used for provisioning of card information to a secure element. Here, however, the secure clement will be provided with the URL or IP Address for the payment processing service provider (most likely by the online retailer). This URL or IP Address is preferably authenticated by the secure element 120 (using, for example, the Controlling Authority provisions found in the Global Platform standard version 2.2 or later) before the secure channel is used for the outgoing transmissions of the user's selected credential. The logic necessary to command the secure element 120 in a device 50 can be deployed on devices through one or more APIs, which may be provided as part of an SDK to interne retailers for their incorporation in the check-out flow of their website or apps.
[0030] With the secure channel open, the consumer, in step 514 , may be prompted by the communication device to select which card (credential) they would like to use for payment. Of course, if only a single credential is stored in the secure element, that credential may be automatically selected and step 514 need not be performed.
[0031] Once a card is selected, the secure element is activated and the credential stored in the secure element for the card is transferred, via the secure channel, to a secure server at the payment processing service provider in step 516 (i.e., Issuance System of FIGS. 1 a and 1 b ). For purposes of this process, it is assumed that the card data for the selected card has already been provisioned and stored in the secure clement, either via the methods described above, or in any other way. The stored card data therefore preferably includes additional information beyond what can be visually seen on the face of the consumer's plastic payment card, such as the information stored in the magnetic strip and/or smart card chip of the card.
[0032] In present day communication devices, when a secure element is activated, the relevant credential content is passed to the NFC baseband of the communication device. Accordingly, in such communication devices, it may be necessary to obtain the card data as it is being passed to the NFC baseband and redirect it to the communication device's data transceiver so that it can be sent to the payment processing service provider. However, it is contemplated that the secure element in a communication device may also be configured such that activation of the secure element 120 directly passes the relevant content to the data transceiver. The communication device 50 also preferably transmits to the payment processing service provider additional information relating to transaction, such as information indicating the amount of the transaction and/or the internet retailer associated with the transaction.
[0033] In step 516 , the applicable applet in the secure element on the communication device generates a unique secure token based upon (1) card information including PAN, expiration date and other information available in Track 1 and/or Track 2 card data and (2) a symmetric and/or asymmetric key based on public key infrastructure technology, and (3) counter value (equivalent to an ATC value provided in a dCVV-compliant payment card) and transmits the unique secure token to the payment processing service provider (the ‘acquirer’ of the transaction on behalf of the merchant), along with addition information (such as time information, merchant ID, valid card number, expiration date, credit-card limit, card usage, CVV) sufficient to enable the secure token to be interpreted and/or recreated and/or paired with a valid card on file and/or user account by the payment processing server and/or an issuer server associated with an issuing bank. Thus, the payment processing service provider in effect acts as the equivalent of a contactless payment reader at a merchant, such as those used for NFC transactions. The issuer bank can then use the full payment card data, which was provided from the consumer's secure clement 120 , to determine if the card data is valid using the same fraud mitigation measures used when contactless payment purchases are made at physical merchants.
[0034] Upon receiving a valid unique secure token, the secure server (i.e., issuance system) at the payment processing service provider may trigger presentation of the appropriate card data to the issuing bank in order to process the transaction as a Card Present Transaction, as set forth in step 518 . In one embodiment, while waiting for bank approval, the consumer may be instructed to wait while the transaction is approved, similar to what a consumer experiences in a typical internet merchant purchase.
[0035] Upon approval (or denial) from the bank, the normal internet purchase completion experience continues as per existing internet purchase behavior. As such procedures are well-known in the art, they are not discussed in further detail herein.
[0036] FIG. 3 illustrates a second exemplary process for enabling smart card-based card payment data to be used when making purchases from internet retailers. In this process, rather than transferring the actual card data from the secure element to the secure server at the payment processing service provider, the system may be configured to virtualize the type of card data presented to the issuing bank in the foregoing example on the issuer adapter ( FIG. 1 ). As will be understood by one of ordinary skill in the art, this process can be implemented once the phone and the card data stored in the communication device's secure element has been validated by a trusted source (i.e., trusted by a merchant services party), through any number of industry standard authentication processes. By using a token to trigger the use of the secure transaction information previously stored in the issuer adapter, the potential latency in transmissions and processing can be significantly decreased.
[0037] In the process described in FIG. 3 , steps 502 - 514 are identical to those described in the embodiment of FIG. 2 . Step 616 differs in that rather than generating the secure transaction data discussed in association with step 516 above, a secure token (preferably having a smaller data payload than the secure transaction data) that references the secure transaction data previously stored on the issuer adapter is generated. Step 616 may be working in the background and need not wait until an actual transaction process has been commenced. The secure token generated in step 616 , is needed however in step 618 for transmission to the secure server which must occur at the time of the desired transaction in substantially real time. Once the secure token is transmitted to the secure server, it validates the secure token and if the secure token is valid presents the previously stored secure transaction data on the issuer adapter to the merchant services party.
[0038] Any of the devices described herein may include at least one processor (e.g., microprocessor) and at least one memory or other non-transitory computer readable medium. The memory may include ROM, RAM as well as one or more removable memory cards. The computer readable instructions, when executed by the at least one processor, may cause the device to perform the functions described herein attributed to the device.
[0039] The foregoing description and drawings merely explain and illustrate the invention and the invention is not limited thereto. While the specification is described in relation to certain implementation or embodiments, many details are set forth for the purpose of illustration. Thus, the foregoing merely illustrates the principles of the invention. For example, the invention may have other specific forms without departing from its spirit or essential characteristic. The described arrangements are illustrative and not restrictive. To those skilled in the art, the invention is susceptible to additional implementations or embodiments and certain of these details described in this application may be varied considerably without departing from the basic principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and, thus, within its scope and spirit. | Increasing security of financial transactions conducted over the Internet is disclosed. In an example, an apparatus may be configured to prompt a user for authorization to permit a pending purchase initiated by a purchase initiating device. The apparatus may establish, via a mobile network interface, a secure communication channel with a server and communicate a credential via the secure communication channel. The apparatus may generate a token based on the credential and communicate the token to the server via the mobile network interface. | 6 |
[0001] This invention relates to a process for preparing halopropyldimethylchlorosilanes which are useful as intermediates for the synthesis of various silane coupling agents and as modifiers for silicone fluid.
BACKGROUND OF THE INVENTION
[0002] Halopropylchlorosilane compounds are used as intermediates for the synthesis of various silane coupling agents and as modifiers for silicone fluid. These compounds are generally synthesized by reacting allyl halides with hydrogenchlorosilane compounds such as trichlorosilane, methyldichlorosilane and dimethylchlorosilane. In the reaction, platinum and rhodium-containing compounds are used as the catalyst.
[0003] The process of preparing halopropylchlorosilane compounds using platinum-containing compounds is disclosed, for example, in U.S. Pat. Nos. 2,823,218, 3,814,730, 3,715,334, 3,516,946, 3,474,123, 3,419,593, 3,220,922, 3,188,299, 3,178,464, and 3,159,601. The process using rhodium-containing compounds is disclosed, for example, in U.S. Pat. Nos. 3,296,291 and 3,564,266. Most of these processes use trichlorosilane and methyldichlorosilane as the hydrogenchlorosilane compound.
[0004] The use of trichlorosilane and methyldichlorosilane as the hydrogenchlorosilane compound is described in many patents as noted above. However, the use of dimethylchlorosilane is described in few patents because of low selectivity of reaction, although the end products, halopropyldimethylchlorosilane compounds are useful as intermediates for the synthesis of various silane coupling agents and as modifiers for silicone fluid. The only known process is Japanese Patent No. 2938731 directed to the preparation of a halopropyldimethylchlorosilane compound using an iridium complex. This process, however, suffers from the problem that a large amount of the expensive iridium complex must be used as the catalyst, and is thus not regarded as advantageous in practicing on an industrial scale.
SUMMARY OF THE INVENTION
[0005] An object of the invention is to provide a simple process for preparing halopropyldimethylchlorosilanes on an industrial scale.
[0006] The invention pertains to a process for preparing a halopropyldimethylchlorosilane of the following general formula (1):
XCH 2 CH 2 CH 2 Si(CH 3 ) 2 Cl (1)
[0007] wherein X is chlorine, bromine or iodine, by reacting dimethylchlorosilane with an allyl halide of the following general formula (2):
XCH 2 CH═CH 2 (2)
[0008] wherein X is as defined above in the presence of an iridium catalyst. Quite unexpectedly, the inventor has found that deactivation of the iridium catalyst during reaction is suppressed by adding an internal olefin compound of the following general formula (3) to the reaction system.
[0009] Herein R 1 and R 2 each are a monovalent hydrocarbon group having 1 to 10 carbon atoms, or R 1 and R 2 may together form a ring, R 3 and R 4 each are hydrogen or a monovalent hydrocarbon group having 1 to 10 carbon atoms. Even when the amount of the iridium catalyst used is reduced, the halopropyldimethylchlorosilane is produced in high yields.
[0010] The invention provides a process for preparing a halopropyldimethylchlorosilane of the general formula (1):
XCH 2 CH 2 CH 2 Si(CH 3 ) 2 Cl (1)
[0011] by reacting dimethylchlorosilane with an allyl halide of the general formula (2):
XCH 2 CH═CH 2 (2)
[0012] in the presence of an iridium catalyst, characterized in that the reaction is effected in the presence of a compound of the general formula (3):
[0013] Herein, X and R 1 to R 4 are as defined above.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] The starting reactant to be reacted with dimethylchlorosilane is an allyl halide of the general formula (2):
XCH 2 CH═CH 2 (2)
[0015] wherein X is chlorine, bromine or iodine. Specifically, the allyl halides are allyl chloride, allyl bromide and allyl iodide. The amount of the allyl halide used is not critical although it is preferred to use 0.5 to 2.0 mol, especially 0.9 to 1.2 mol of allyl halide per mol of dimethylchlorosilane.
[0016] The iridium catalyst used herein encompasses iridium salts and iridium complexes. Exemplary iridium salts are iridium trichloride, iridium tetrachloride, chloroiridic acid, sodium chloroiridate and potassium chloroiridate. The iridium complexes include those represented by the following general formula (4):
[Ir(R)Y] 2 (4)
[0017] wherein R is a diene compound and Y is chlorine, bromine or iodine. Illustrative examples of the iridium complexes of formula (4) include di-μ-chlorobis(μ-1,5-hexadiene)diiridium, di-μ-bromobis(μ-1,5-hexadiene)diiridium, di-μ-iodobis(μ-1,5-hexadiene)diiridium, di-μ-chlorobis(μ-1,5-cyclooctadiene)diiridium, di-μ-bromobis(μ-1,5-cyclooctadiene)diiridium, di-μ-iodobis(μ-1,5-cyclooctadiene)diiridium, di-μ-chlorobis(μ-2,5-norbornadiene)diiridium, di-μ-bromobis(μ-2,5-norbornadiene)diiridium, and di-μ-iodobis(μ-2,5-norbornadiene)diiridium.
[0018] No particular limit is imposed on the blending ratio of the iridium catalyst although it is preferred to use the iridium catalyst in such amounts as to give 0.000001 to 0.01 mol, especially 0.00001 to 0.001 mol of iridium atom per mol of dimethylchlorosilane. Less than 0.000001 mol of the catalyst may fail to exert catalytic effects whereas more than 0.01 mol of the catalyst may not provide reaction promoting effects corresponding to the increment of the catalyst.
[0019] According to the invention, the reaction of dimethylchlorosilane with the allyl halide of formula (2) is carried out in the presence of not only the iridium catalyst, but also an internal olefin compound of the formula (3).
[0020] Herein R 1 and R 2 each are a monovalent hydrocarbon group having 1 to 10 carbon atoms, or R 1 and R 2 , taken together, may form a ring. R 3 and R 4 each are hydrogen or a monovalent hydrocarbon group having 1 to 10 carbon atoms. Illustrative examples of the compound of formula (3) include 2-hexene, 3-hexene, 2-heptene, 2-octene, 4-octene, 2-decene, 5-decene, cyclopentene, cyclohexene, 2-norbornene, 1,3-cyclohexadiene, 1,4-cyclohexadiene, 4-vinyl-1-cyclohexene, 1,5-cyclooctadiene, 2,5-norbornadiene, 5-vinyl-2-norbornene, and limonene. From the reactivity and catalyst stability standpoints, 1,5-cyclooctadiene is most preferred.
[0021] No particular limit is imposed on the amount of the compound of formula (3) used although it is preferred to use 0.5 to 10,000 mol, especially 1 to 1,000 mol of the compound per mol of iridium atom in the iridium catalyst. Less than 0.5 mol of the compound may fail to exert the desired effects whereas more than 10,000 mol of the compound may fail to provide effects corresponding to that amount and cause more by-products to form, resulting in reduced yield and purity.
[0022] The reaction will proceed in a solventless system although a solvent is used if desired. Useful solvents include hydrocarbon solvents such as pentane, hexane, cyclohexane, heptane, octane, isooctane, benzene, toluene, and xylene; ether solvents such as diethyl ether, tetrahydrofuran, and dioxane; ester solvents such as ethyl acetate and butyl acetate; aprotic polar solvents such as acetonitrile; and chlorinated hydrocarbon solvents such as dichloromethane and chloroform, which may be used alone or in admixture of two or more.
[0023] The reaction temperature is not critical. A temperature in the range of about 0° C. to about 200° C., especially about 10° C. to about 100° C. is preferred when reaction is effected under atmospheric pressure or under pressure. The reaction time is usually from about 1 hour to about 10 hours.
[0024] According to the invention, the above-described reaction yields a halopropyldimethylchlorosilane of the general formula (1):
XCH 2 CH 2 CH 2 Si(CH 3 ) 2 Cl (1)
[0025] wherein X is chlorine, bromine or iodine. Specifically, the silanes are 3-chloropropyldimethylchlorosilane, 3-bromopropyldimethylchlorosilane, and 3-iodopropyldimethylchlorosilane.
EXAMPLE
[0026] Examples of the invention are given below by way of illustration and not by way of limitation.
Example 1
[0027] A flask equipped with a stirrer, reflux condenser, dropping funnel and thermometer was charged with 153.0 g (2.0 mol) of allyl chloride, 67.2 mg (0.0001 mol) of di-μ-chlorobis(μ-1,5-cyclooctadiene)diiridium, and 0.43 g (0.004 mol) of 1,5-cyclooctadiene and heated at 35° C. Once the internal temperature was stabilized, 189.2 g (2.0 mol) of dimethylchlorosilane was added dropwise over 6 hours. During the dropwise addition, the reaction mixture continued to be exothermic. After the completion of dropwise addition, the reaction solution was stirred for one hour at 40° C. The reaction solution was distilled, collecting 317.2 g of a fraction having a boiling point of 84° C./6.7 kPa, which was 3-chloropropyldimethylchlorosilane (yield 92.7%).
Example 2
[0028] A flask equipped with a stirrer, reflux condenser, dropping funnel and thermometer was charged with 153.0 g (2.0 mol) of allyl chloride, 67.2 mg (0.0001 mol) of di-μ-chlorobis(μ-1,5-cyclooctadiene)diiridium, and 0.33 g (0.004 mol) of cyclohexene and heated at 35° C. Once the internal temperature was stabilized, 189.2 g (2.0 mol) of dimethylchlorosilane was added dropwise over 6 hours. During the dropwise addition, the reaction mixture continued to be exothermic. After the completion of dropwise addition, the reaction solution was stirred for one hour at 40° C. The reaction solution was analyzed by gas chromatography, finding a conversion of 81.5%.
Comparative Example 1
[0029] Reaction was effected as in Example 1 except that 1,5-cyclooctadiene was omitted. The reaction mixture ceased to be exothermic after approximately 50% of the predetermined amount of dimethylchlorosilane had been added dropwise. The final conversion was as low as 50.5%.
Example 3
[0030] A flask equipped with a stirrer, reflux condenser, dropping funnel and thermometer was charged with 153.0 g (2.0 mol) of allyl chloride, 1.9 g (0.0002 mol) of a 2 wt % butanol solution of chloroiridic acid, and 2.2 g (0.02 mol) of 1,5-cyclooctadiene and heated at 35° C. Once the internal temperature was stabilized, 189.2 g (2.0 mol) of dimethylchlorosilane was added dropwise over 6 hours. During the dropwise addition, the reaction mixture continued to be exothermic. After the completion of dropwise addition, the reaction solution was stirred for one hour at 40° C. The reaction solution was analyzed by gas chromatography, finding a conversion of 73.9%.
Comparative Example 2
[0031] Reaction was effected as in Example 3 except that 1,5-cyclooctadiene was omitted. After one hour of stirring at 40° C., the conversion was as low as 8.3%.
[0032] There has been described a process for the preparation of a halopropyldimethylchlorosilane compound from dimethylchlorosilane and an allyl halide in the presence of an iridium catalyst wherein an internal olefin compound is added to the reaction system for suppressing deactivation of the iridium catalyst during reaction, whereby the halopropyldimethylchlorosilane is produced in high yields despite a smaller amount of the iridium catalyst. The invention enables the efficient production of halopropyldimethylchlorosilane on an industrial scale.
[0033] Japanese Patent Application No. 2000-142128 is incorporated herein by reference.
[0034] Although some preferred embodiments have been described, many modifications and variations may be made thereto in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described without departing from the scope of the appended claims. | A halopropyldimethylchlorosilane is prepared by reacting dimethylchlorosilane with an allyl halide in the presence of an iridium catalyst. The reaction is effected in the presence of an internal olefin compound, typically 1,5-cyclooctadiene. The internal olefin compound suppresses deactivation of the iridium catalyst during reaction. Using a smaller amount of the iridium catalyst, the process produces the halopropyldimethylchlorosilane in high yields. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention claims priority from U.S. Patent Application No. 60/829,181 filed Oct. 12, 2006 entitled “QAM DIGITAL QUALITY INDICATOR”, which is incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to a system for calculating a digital quality index (DQI), which is a measure of the impairments in a received quadrature amplitude modulated (QAM) digital signal in a CATV cable system, and in particular to a DQI system used to detect impairments and quantify the results over a predetermined range.
BACKGROUND OF THE INVENTION
Digitally modulated signals are used to transport high-speed data, video and voice on cable networks. The high-speed signals are subject to a variety of impairments that can seriously impact the quality and reliability of the services being provided. Unfortunately, measuring the signal level or looking at the display on a conventional spectrum analyzer isn't enough to fully troubleshoot problems or characterize the health of a digitally modulated signal.
Delivery of data services over cable television systems is typically compliant with a data-over-cable-service-interface-specifications (DOCSIS) standard. The content of the digital signal is typically modulated using quadrature amplitude modulation (QAM). Current cable QAM standards use conventional forward error correction (FEC) and interleaving techniques to transmit the data downstream. FEC is a system of error control for data transmission in which the receiving device detects and corrects fewer than a predetermined number or fraction of bits or symbols corrupted by transmission errors. FEC is accomplished by adding redundancy to the transmitted information using a predetermined algorithm. However, impairments that exceed the correction capability or the burst protection capacity of the interleaving will not be corrected, and the digital data will be corrupted. Accordingly, technicians need to be able to detect impairments above and below the threshold at which digital signals are corrupted to be able to detect current and potential problems.
As with all modulation schemes, QAM conveys data by changing some aspect of a carrier signal, or the carrier wave, which is usually a sinusoid, in response to a data signal. In the case of QAM, the amplitude of two waves, 90° out-of-phase with each other, i.e. in quadrature, are changed, e.g. modulated or keyed, to represent the data signal.
When transmitting two signals by modulating them with QAM, the transmitted signal will be of the form:
s ( t )= I ( t )cos(2 πf 0 t )+ Q ( t )sin(2π f 0 t )
where I(t) and Q(t) are the modulating signals and f 0 is the carrier frequency.
At the receiver, the two modulating signals can be demodulated using a coherent demodulator, which multiplies the received signal separately with both a cosine and sine signal to produce the received estimates of I(t) and Q(t), respectively. Due to the orthogonality property of the carrier signals, it is possible to detect the modulating signals independently.
In the ideal case I(t) is demodulated by multiplying the transmitted signal with a cosine signal:
r
i
(
t
)
=
s
(
t
)
cos
(
2
π
f
0
t
)
=
I
(
t
)
cos
(
2
π
f
0
t
)
cos
(
2
π
f
0
t
)
+
Q
(
t
)
sin
(
2
π
f
0
t
)
cos
(
2
π
f
0
t
)
Using standard trigonometric identities:
r
i
(
t
)
=
1
2
I
(
t
)
[
1
+
cos
(
4
π
f
0
t
)
]
+
1
2
Q
(
t
)
sin
(
4
π
f
0
t
)
=
1
2
I
(
t
)
+
1
2
[
I
(
t
)
cos
(
4
π
f
0
t
)
+
Q
(
t
)
sin
(
4
π
f
0
t
)
]
Low-pass filtering r i (t) removes the high frequency terms, i.e. containing (4πf 0 t)), leaving only the I(t) term, unaffected by Q(t). Similarly, we may multiply s(t) by a sine wave and then low-pass filter to extract Q(t).
A constellation diagram is a representation of a signal modulated by a digital modulation scheme, such as quadrature amplitude modulation or phase-shift keying. The constellation diagram displays the signal as a two-dimensional scatter diagram in the complex plane at symbol sampling instants, i.e. the constellation diagram represents the possible symbols that may be selected by a given modulation scheme as points in the complex plane. Measured constellation diagrams can be used to recognize the type of interference and distortion in a signal.
By representing a transmitted symbol as a complex number and modulating a cosine and sine carrier signal with the real and imaginary parts, respectively, the symbol can be sent with two carriers, referred to as quadrature carriers, on the same frequency. A coherent detector is able to independently demodulate the two carriers. The principle of using two independently modulated carriers is the foundation of quadrature modulation.
As the symbols are represented as complex numbers, they can be visualized as points on the complex plane. The real and imaginary axes are often called the in phase, or I-axis and the quadrature, or Q-axis. Plotting several symbols in a scatter diagram produces the constellation diagram. The points on a constellation diagram are called constellation points, which are a set of modulation symbols that comprise the modulation alphabet.
In QAM, the constellation points are usually arranged in a square grid with equal vertical and horizontal spacing, although other configurations are possible. The most common forms are 16-QAM, 64-QAM, 128-QAM and 256-QAM. By moving to a higher-order constellation, it is possible to transmit more bits per symbol; however, if the mean energy of the constellation remains the same, in order to make a fair comparison, the points must be closer together and are thus more susceptible to noise and other corruption, i.e. a higher bit error rate. Accordingly, a higher-order QAM will deliver more data less reliably than a lower-order QAM. 64-QAM and 256-QAM are often used in digital cable television and cable modem applications. In the United States, 64-QAM and 256-QAM are the mandated modulation schemes for digital cable as standardised by the SCTE in the standard ANSI/SCTE 07 2000.
A typical QAM analyzer design includes a user interface, e.g. a keypad and a display, and possibly an Ethernet or other external connection for connection to a personal computer. A tuner is used to select a digitally modulated signal of interest, and a QAM demodulator provides several elements indicative of the received signal, such as carrier frequency acquisition, carrier phase tracking, symbol rate tracking, adaptive equalizer, and J.83 channel decoding. By probing into the elements of the QAM demodulator one can retrieve information on MER, pre- and post-FEC BER, and channel response, which is part of physical layer testing.
To troubleshoot a subscriber's premises with a signal problem, a technician will travel to the premises or a hub nearby, and conduct a variety of tests on the digitally modulated signal, e.g. RF level, MER, pre- and post-FEC BER, and an evaluation of the constellation for impairments. In addition, the technician may look at the equalizer graph for evidence of micro-reflections, and check in-channel frequency response and group delay. Moreover, if the QAM analyzer is able, the measurements are repeated in the upstream direction. Unfortunately, all of the test results require a certain degree of experience, knowledge and skill to interpret, potentially resulting in differing explanations for the problem depending on the technician. BER measurements require that the test instrument have the capability to fully decode the digital signal, and require long sampling time to detect low bit error rates. Furthermore, post-FEC BER shows only the impairments the exceed the correction capability of the FEC and interleaving
United States Patent Applications Nos. 2005/0144648 published Jun. 30, 2005 in the name of Gotwals et al; 2005/0281200 published Dec. 22, 2005 to Terreault; 2005/0286436 published Dec. 29, 2005 to Flask; and 2005/0286486 published Dec. 29, 2005 to Miller disclose conventional cable signal testing devices. U.S. Pat. Nos. 6,611,795 issued Aug. 26, 2003 to Cooper, and 7,032,159 issued Apr. 18, 2006 to Lusky et al, and United States Patent Application No. 2003/0179821 published Sep. 25, 2003 to Lusky et al relate to error correcting methods. PCT Patent Publication No. WO 2006/085275 published Aug. 17, 2006 to Moulsley et al relates to estimating the BER based on the sampled amplitude of the signal.
An object of the present invention is to overcome the shortcomings of the prior art by providing a fast and sensitive measurement of impairments on a QAM digital channel without requiring full decode capability of the QAM signal, and without requiring a vast amount of expertise.
SUMMARY OF THE INVENTION
Accordingly, the present invention relates to a method of determining an indication of the quality on a QAM digital signal on a cable network with forward error correction comprising the steps of:
a) determining a first bit error rate (BER) of the digital signal prior to forward error correction (FEC);
b) determining a second bit error rate after forward error correction (FEC);
c) determining a digital quality index (DQI) on a predetermined scale based on the first and second bit error rates; and
d) displaying the DQI to provide an indication of the quality of the QAM digital signal on the cable network.
Another embodiment of the present invention relates to a testing device for generating an indication of the quality on a QAM digital signal on a cable network with forward error correction (FEC) comprising:
an input port for receiving the QAM digital signal;
first bit error rate (BER) generating means for determining the BER of the QAM digital signal prior to FEC;
second first bit error rate (BER) generating means for determining the BER of the QAM digital signal after FEC;
digital quality index generating means for determining a digital quality index (DQI) of the QAM digital signal on a predetermined scale based on the first and second BER; and
a display for displaying the DQI to provide an indication of the quality of the QAM digital signal on the cable network.
Another embodiment of the present invention relates to a method of determining a bit error rate of a QAM digital signal on a cable network with forward error correction (FEC) comprising the steps of:
a) determining an error voltage V ERR of the digital signal once every 10 to 50 microseconds;
b) determining a first bit error rate prior to FEC based on a predetermined statistical relationship between the V ERR and the first BER once every 10 to 50 microseconds; and
c) averaging the first BER every 0.5 to 2 seconds.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in greater detail with reference to the accompanying drawings which represent preferred embodiments thereof, wherein:
FIG. 1 is a schematic representation of the testing device of the present invention;
FIG. 2 is a schematic representation of the subsystems of the testing device of the present invention;
FIG. 3 is a schematic representation of a statistical model for approximating bit error rate prior to and after forward error correcting;
FIG. 4 is a plot of BER prior to FEC vs Error Voltage (V ERR ) for the statistical model of FIG. 3 ;
FIG. 5 is a plot of BER prior to FEC vs BER after FEC for the statistical model of FIG. 3 ;
FIG. 6 is a schematic representation of an alternate embodiment of a statistical model for approximating bit error rate prior to and after forward error correcting;
FIG. 7 is a schematic representation of a I-Q corner analyzer of the statistical model of FIG. 6 ;
FIG. 8 are constellation diagrams for 64, 128 and 256 QAM signals illustrating the corner and middle squares;
FIG. 9 a is a flow chart for determining the DQI in accordance with BER prior to and after FEC;
FIG. 9 b is an alternative flow chart for determining the DQI in accordance with BER prior to and after FEC;
FIG. 10 is an alternative flow chart for determining the DQI in accordance with BER prior to and after FEC;
FIG. 11 is a chart representative of the DQI in relation to BER prior to and after the FEC; and
FIG. 12 is an alternative flow chart for determining an enhanced DQI in accordance with level measurements and adaptive equalizer tap values.
DETAILED DESCRIPTION
With reference to FIG. 1 , the DQI testing device 1 of the present invention includes four subsystems: a receiver and measurement subsystem 2 for receiving a quadrature amplitude modulated (QAM) signal and for determining bit error rates prior to and after forward error correction, a scoring subsystem 3 for generating a digital quality index (DQI) number on a predetermined scale, e.g. 0 to 10, based on the aforementioned bit error rates, an analysis subsystem 4 for analyzing the determined information, and a display subsystem 5 for relating the DQI number and any addition information to the technician utilizing the testing device 1 .
With reference to FIG. 2 , the receiver and measurement subsystem 2 includes an input port 10 for receiving the QAM digital signal from a cable network, a tuner 11 for selecting a desired cable channel to test, and a QAM demodulator 12 for demodulating the QAM signal into I and Q signals. In a full service testing device, the I and Q signals are transmitted to a constellation sampler 13 and a symbol decoder 14 , which decodes the digital signal into a decoded signal. The constellation sampler 13 generates a constellation diagram 15 . The symbol decoder 14 determines the modulation error ratio (MER) for display at readout 16 , and transmits the decoded signal to a forward error correction (FEC) decoder 17 . The FEC decoder 17 performs error correction on the decoded signal, and determines a bit error rate (BER) before and after the error correction for display at readouts 18 and 19 , respectively.
The QAM demodulator 12 also provides a QAM decode error voltage (V ERR ), which can be used to compute the Modulation Error Rate (MER), an estimate of the signal to noise ratio (SNR) of the digital signal, to a bit error rate (BER) calculator 21 to convert the V ERR to a bit error rate (BER). The V ERR value from the QAM demodulator 12 is multiplied by different scale factors depending on the QAM modulation of the signal, for example:
Scale Factors
Annex A
Annex B
64 QAM
0.67
0.50
128 QAM
1.34
N/A
256 QAM
1.32
1.00
MER(dB)=20 log 10 (V REF /V ERR )
EVM(dB)=20 log(V ERR /V REF ), or EVM(%)=(V ERR /V REF )*100%
The reference voltage V REF is the RMS voltage of an ideal signal.
MER is commonly used in digital communications as an approximation of SNR or as a substitute for it. A true SNR measurement is difficult to perform on a digital signal. Accordingly, the term SNR analyzer is used for the subsystem that uses the filtered error voltages to get pre- and post-FEC BER estimates.
The scoring subsystem 3 can use the pre-FEC BER and the post-FEC BER determined from the FEC decoder 17 , as shown by the which will necessitate that the digital signal be fully decoded, and a great deal of time to measure low BERs. Alternatively, the constellation sampler 13 , the symbol decoder 14 , the constellation diagram 15 , the MER readout 16 , and the FEC decoder 17 can be eliminated, and the BER calculator 21 can be used to estimate the pre-FEC BER and the post-FEC BER. The BER calculator 21 includes an SNR analyzer 30 , illustrated in FIG. 3 or, in a preferred embodiment, a combination of the SNR analyzer 30 with an I-Q corner analyzer 41 , as in FIG. 6 . All of the aforementioned systems are under the control of a microcomputer 25 with a keyboard or graphical interface 26 .
The SNR analyzer 30 receives filtered V ERR samples, e.g. from a fast filter 31 , which is sampled once every 10 to 50 microseconds, and a pre-FEC BER prior to the forward error correction (FEC) is calculated at 32 in accordance with a predetermined statistical relationship between V ERR and pre-FEC BER. The average pre-FEC BER is determined at 33 , and forwarded to the scoring subsystem 3 or combined with the pre-FEC BER provided by the I-Q corner analyzer 41 , as hereinafter described. In order for the present invention to see narrow ingress pulses, the estimated V ERR must be sampled at a higher rate than would normally be used to measure MER. Hardware filtering, i.e. fast filter 31 , is needed if the sample rate is lower than the QAM symbol rate, but the time constant of the filter 31 must be appropriate for the fast sample rate required.
Simulations and mathematical modeling were conducted to determine a mathematical relationship between SNR (or V ERR ) to pre-FEC BER. An exponential function provides a good approximation of the relationship between the V ERR and the pre-FEC BER; however, fails when high V ERR values cause the pre-FEC BER to go over 1, as seen in FIG. 4 . Accordingly, in a first embodiment the pre-FEC estimated BER f is computed from the scaled V ERR value x using a modified exponential equation:
f
(
x
)
=
c
1
+
a
ⅇ
-
bx
with a>0, b>0 and 0≦c≦1, and preferably wherein a=1.42857×10 12 , b=2.65×10 −4 , and c=0.2, which is graphically illustrated in FIG. 4 . The values of the constants a, b, and c are selected based on the specific QAM decoder hardware by analyzing data sampled with know signal impairments.
Subsequently, the post-FEC estimated BER g is calculated at 34 in accordance with a predetermined statistical relationship between pre-FEC BER and post-FEC BER. Additional simulations and mathematical modeling were conducted to determine a mathematical relationship between pre-FEC BER and post-FEC BER. In a preferred embodiment, the post-FEC estimated BER x is determined using the equation:
g ( x )= xe −p/x q
with p and q>0, and wherein p 0.105277 and q 0.55, which is graphically illustrated in FIG. 5 . Again, the values of the constants p and q are selected based on the specific QAM decoder hardware by analyzing data sampled with know signal impairments.
The lowest M of N post-FEC BER estimates are averaged at 35 , and deinterleaved post-FEC BER estimates are averaged at 36 . The average post-FEC BER is forwarded to the scoring subsystem 3 or combined with the post-FEC BER provided by the I-Q corner analyzer 41 , as hereinafter described.
FEC divides the data stream into fixed-length blocks and adds redundant data to each block in order to correct a small number of errors occurring in the transmission of the block. A noise burst often corrupts more consecutive QAM symbols than can be corrected in a single block. In order to protect the data from corruption by long noise bursts, the sender interleaves data from several blocks prior to transmitting the data. The receiver deinterleaves the data to restore the original order within the FEC blocks. Interleaving increases the burst protection capacity by multiplying the number of correctable symbols of one FEC block by the number of blocks being interleaved. The burst correction time can be computed from the symbol rate and the number of consecutive symbols that can be corrected. Interleaving does not increase the overall ratio of correctable symbols to total symbols contained within a block. As a result, interleaving to correct longer noise bursts requires that the minimum time between noise bursts also be increased. The minimum time between noise bursts is called the interleaver latency time, and can be computed from the symbol rate and the total length of all FEC blocks being interleaved. The symbols may be the same, but often the FEC symbol is 7 bits long and the QAM symbol is 6 or 8 bits long. The data is grouped into FEC symbols, then interleaved, then regrouped into QAM symbols.
The post-FEC BER model simulates the effects of interleaving by keeping a rolling history of the values from the pre to post-FEC BER block 34 . Whenever block 35 receives a new value, the oldest value is discarded. During an initialization phase of the averaging step 35 of the SNR analyzer 30 , values are merely accumulated; however, once N values are received, a new value is output for each new value input. The output values consist of the average of the lowest M values of the N values stored in the rolling history. Accordingly, the burst protection effects of interleaving are approximated, when used in conjunction with FEC. The values M and N are selected to approximate the burst correction capacity and latency times of the interleaver being used. M is the sample burst correction time divided by the sample period, and N is the interleaver latency time divided by the sample period.
Averaging step, illustrated by blocks 33 and 36 are conducted at a very high speed, e.g. once every 5 to 50 (or 10 to 25) microseconds, over a longer measurement interval, e.g. 0.5 to 2 seconds or more, ideally 1 second. Accordingly, overall average post and pre-FEC BER values are obtained by averaging the BER values for additive white Gaussian noise (AWGN), which provides a fairly accurate approximation for real-world impairments, especially impulse noise.
With reference to FIGS. 6 and 7 , the BER calculator 21 preferably includes an I-Q corner analyzer 41 providing an additional means to determine the pre-FEC and the post-FEC BER values, which are combined with the aforementioned means based on the V ERR to obtain more accurate pre-FEC and post-FEC BER values.
A constellation cell selector 42 of the I-Q Corner Analyzer 41 receives 10 bit I and Q signal samples once every 5 to 50 (or 10 to 25) microseconds (ideally faster dependent on sampling hardware) from the QAM demodulator 12 via signal decoder 14 , identifies the grid square to which each sample belongs, and then transmits the grid square to the corner detector 43 , and to the middle detector 44 , which identify the samples that belong to the corner and middle regions, respectively. Examples of corner and middle squares in 64, 128 and 256 QAM constellation diagrams are illustrated in FIG. 8 . The middle squares comprise the 10% to 20% of the squares closest to the middle of the constellation diagram, as measured using the Euclidean distance from the center of the square to the middle of the constellation diagram i.e. 2 to 3 squares in each direction from the center, while the corner squares are the 4% to 8% of the squares farthest from the middle of the constellation diagram, e.g. the extreme corner squares of the constellation diagram and/or those squares adjacent thereto.
An error vector is calculated utilizing the 10 bit I and Q signal samples from the QAM demodulator 12 by an error vector calculator 45 . An error metric is determined at 46 utilizing horizontal and vertical components of the error vector, according to the equation:
E=x 4 +y 4
where E is the error magnitude and x and y are the horizontal and vertical components of the error vector. The error metric is computed for all grid squares in the corner and middle regions of the constellation diagram 15 , as illustrated in FIG. 8 . Separate averages of the error metric are computed for the corner region and the middle region at 47 and 48 , respectively, utilizing the error metric, every 0.5 to 2 seconds, i.e. every time a new DQI value is calculated. After averaging at 47 and 48 , the average value is divided by a scale factor based on the modulation, e.g. 16 for 256 QAM, 81 for 128 QAM, and 256 for 64 QAM, to normalize the error magnitude. The aforementioned scale factors assume that I and Q have 10-bit resolution, which is a hardware dependency.
A pre-FEC BER prior to the forward error correction (FEC) is determined at 49 in accordance with a predetermined statistical relationship between the corner average error metric and pre-FEC BER. In a preferred embodiment, the corner pre-FEC BER model is a simple power function:
p ( x )= ax b
where x is the corner average error metric, p is the pre-FEC BER estimate, a=2.92567E-19, and b=3.14057. The values of the constants a and b are selected based on the specific QAM decoder hardware by analyzing data sampled with know signal impairments.
A post-FEC BER prior to the forward error correction (FEC) is determined at 50 in accordance with a predetermined statistical relationship between the pre-FEC BER and the post-FEC BER. Preferably, the pre- to post-FEC BER model is given by the equation
q
(
p
)
=
p
ⅇ
k
mp
r
where p is the pre-FEC BER estimate, q is the post-FEC BER estimate, k=−0.105277, m=12.5893, and r=0.55. The values of the constants p, q, m and k are selected based on the specific QAM decoder hardware by analyzing data sampled with know signal impairments.
A corner weight calculator 51 calculates a corner weight, which is preferably given by the equations
r
=
max
{
1
,
c
(
m
+
k
m
)
k
c
}
w
=
w
max
(
1
-
1
r
)
where w is the corner weight, c is the corner average error metric, and m is the middle average error metric. The constants include maximum corner weight w max =0.1, middle offset k m =2100, and corner threshold k c =1.75.
With reference to FIG. 6 , the BER estimates from the combined SNR (or V ERR ) and corner models for the pre-BER estimates are computed in the SNR-corner combiner 61 using the equation:
p ( s,c,w )=max{ s,cw+s (1− w )}
where s is the SNR model BER, c is the corner model BER, and w is the corner weight. Similarly, the BER estimates from the combined SNR and corner models for the post-BER estimates are computed in the SNR-corner combiner 62 using the same equation.
The scoring subsystem 3 receives the pre-FEC BER and the post-FEC BER estimates from the BER calculator 21 , and provides them to a DQI logic measurement system 71 to determine the DQI on a predetermined scale, e.g. 1 to 5 or 0 to 10. Exemplary algorithms for the logic measurement system 71 are illustrated in FIGS. 9 a and 9 b.
With reference to FIG. 9 a , an initial logic box 81 determines whether the post-FEC BER is equal to or greater than a post minimum threshold, e.g. 1×e −8 . If so, then a second logic box 82 determines whether the post-FEC BER is equal to or greater than a post maximum threshold, e.g. 1×e −4 . If so, then the DQI score is determined to be the lowest rating, e.g. zero, on a predetermined scale, e.g. zero to ten. If not, i.e. the post-FEC BER is between the post minimum and the post maximum thresholds, then the DQI score varies, e.g. logarithmically, between the lowest rating, e.g. 0 and a middle rating, e.g. 5, and can determined by the equation:
DQI=int (−12.5 log(post- FEC BER )−50)/10
If the post-FEC BER is not equal to or greater than, i.e. is less than, the post minimum threshold, e.g. 1×e −8 , then a third logic box 83 determines whether pre-FEC BER is equal to or greater than an prior maximum threshold, e.g. 1×e −4 . If so, i.e. the post-FEC BER is less than the post minimum threshold, but the pre-FEC BER is greater than the prior maximum threshold, then the DQI score is the middle rating on the predetermined scale, e.g. 5.0. If not, then a fourth logic box 84 determines whether the pre-FEC BER is equal to or greater than an prior minimum threshold, e.g. 1×e −8 . If not, i.e. the pre-FEC BER is less than the prior minimum threshold and the post-FEC BER is less than the post minimum threshold, then the DQI score is a highest rating on the predetermined scale, e.g. 10.0, but if so, i.e. the post-FEC BER is less than the post minimum threshold, but the pre-FEC BER is between the prior minimum and prior maximum thresholds, then the DQI score varies, e.g. logarithmically, between the middle rating, e.g. 5 and the highest rating, e.g. 10, and is determined by the equation:
DQI=int (−12.5 log(pre- FEC BER ))/10
In an alternate embodiment illustrated in FIG. 9 b , the fourth logic box 84 is replaced by a modified fourth logic box 84 ′, which determines whether the pre-FEC BER is equal to or greater than a different prior minimum threshold, 1×e −9 . Moreover, if the post-FEC BER is less than the post minimum threshold, but the pre-FEC BER is between the post minimum and post maximum thresholds, then the DQI score varies, i.e. logarithmically, between the middle and highest ratings, e.g. 5 and 10, and is determined by the equation:
DQI=int (−10 log(pre- FEC BER )+10)/10
In a simplified embodiment, illustrated in FIG. 10 , the first logic box 81 is the same as above, but the second logic box 82 is replaced by a modified second logic box 82 ′, which determines whether the post-FEC BER is also equal to or greater than a revised post maximum threshold, e.g. 1×e −6 . If so, then the DQI score is the lowest rating, i.e. 1, if not, i.e. the post-FEC BER is between the post minimum and maximum thresholds, then the DQI score is between the lowest and middle ratings, i.e. 2. The third logic box 83 is also replaced by a modified third logic box 83 ′, which determines whether the pre-FEC BER is equal to or greater than a revised prior maximum threshold, e.g. 1×e −6 . If so, i.e. the post-FEC BER is less than the post minimum threshold, but the pre-FEC BER is greater than the prior maximum threshold, then the DQI score is the middle rating, i.e. 3, if not then the original logic box 84 is considered; however, if the pre-FEC BER is also equal to or greater than the prior minimum threshold, e.g. 1×e −8 , then the DQI score is between the middle and highest ratings, i.e. 4, and if not, i.e. the post-FEC BER is less than the post minimum threshold and the pre-FEC BER is less that the prior minimum threshold, then the DQI score is the highest rating, i.e. 5.
In the scoring subsystem 3 BER averages are read from the measurement subsystem 2 and scored at a rate of 1 to 2 updates per second. FIG. 11 illustrates the general relationship between pre-FEC BER, post-FEC BER and the DQI score, i.e. if there is no post-FEC BER and no significant pre-FEC BER, then the DQI score would be approximately the highest rating, e.g. 10. As the pre-FEC BER increases, while the post-FEC BER remains consistently low, the DQI score ranges from near the highest to the middle rating, e.g. 9 down to 5. As the amount of post-FEC BER also increases, the DQI score decreases from the middle rating down to the lowest rating, e.g. 5 to 0, at which point, significant amounts of both pre-FEC BER and post-FEC BER are found.
With reference to FIG. 12 , an enhanced DQI system 91 enables a DQI receiver and measurement system 92 to evaluate certain adverse network conditions that do not impair the QAM receiver 92 , but could adversely affect consumer-grade receivers. Typically, these adverse network conditions do not affect the pre- and post-BER values coming from the receiver and measurement subsystem 92 ; however, the scoring subsystem 93 can be enhanced in order to use the information provided by the enhancements.
The signal level of the digital channel being tested may fluctuate when amplifiers in the network experience problems with their automatic gain control (AGC) circuitry. The degree of signal impairment varies with the amount and rate of the fluctuations. The signal level may also vary at a rate corresponding to the frequency of the AC power supply driving an amplifier, or in some cases, twice the AC power supply frequency. These variations, commonly called hum, may also introduce impairments in consumer-grade digital receivers.
The DQI scoring subsystem 93 estimates the effects of amplitude fluctuation caused by the AGC circuitry or hum and the effects of linear distortions by quantifying the degree to which each impairment is present, and adjusts, e.g. reduces, the overall DQI score by weighting factors or other means of combining the results. With these enhancements, the scoring subsystem 93 outputs individual scores for each type of impairment as well as a composite score representing overall quality.
In the enhanced receiver and measurement subsystem 92 , the QAM demodulator 12 (see FIG. 2 ) includes an adaptive equalizer component that reduces the effects of micro-reflections, group delay variations, frequency response variations, and other linear distortions of the received QAM digital signal. The adaptive equalizer contains a number of feed-forward equalization (FFE) and decision feedback equalization (DFE) taps. Each tap has an associated complex coefficient value. The demodulator 12 continually adjusts the tap values using the error information provided by each symbol decode. A typical receiver has 16 FFE and 24 DFE taps.
The receiver and measurement subsystem 92 periodically captures and outputs the instantaneous values of the tap coefficients. The tap values are updated at the same rate as the receiver and measurement subsystem 92 provides pre- and post-FEC BER values to the scoring subsystem 93 .
A typical decoder chip in the equalizer enables the tap values to be read one at a time. The measurement subsystem 92 captures a complete set of the tap coefficient values representing the overall equalizer state at a point in time, by first: stopping the automatic updating of the tap values; and then by reading the values from the decoder chip sequentially. After all values are read, normal updating of the equalizer continues.
One advantage of DQI over other digital measurements is its ability to show impairments as a slight lowering of the DQI score, which would otherwise be too small to show up in a pre-FEC BER test or disrupt subscriber services. In particular, the DQI score is lowered by equalizer tap values with magnitudes that are within range, but are close to thresholds at which the equalizer would be unable to adapt.
For yet another enhancement, the receiver and measurement subsystem 92 performs signal level measurements in order to report conditions that can adversely affect the performance of consumer-grade digital receivers, but do not affect the receiver used in the DQI device 91 . In order to measure signal level fluctuations, the measurement subsystem 92 determines the signal level several times during a display update period. The measurement rate must be at least four times the AC power supply frequency in order to detect and quantify hum. The signal level measurement may use any of the following means:
a) The measurement subsystem 92 reads the instantaneous gain setting of an AGC system found in the QAM decoder chip therein to determine the signal level. A lower gain indicates a higher received signal level.
b) One of the FFE taps of the adaptive equalizer is configured to be the main tap, with an imaginary value fixed at zero, whereby the mechanism used to update the tap values is adapted, so that the real value of the main tap represents the received signal level. A lower tap value indicates a higher received signal level.
c) Additional circuitry is included in the measurement subsystem 92 to measure the received signal level without disrupting the QAM decoder.
If the level measurements are performed at a fast enough rate to measure hum, the measurement subsystem 92 outputs separate values for signal level stability and for hum. In order to differentiate between them, the measurement subsystem 92 may use either filtering or a Fourier transform to identify fluctuations occurring at the AC power supply frequency or a multiple thereof.
The cable network carries additional channels with the channel under test, e.g. both analog and digital TV channels, and an ideal QAM receiver will block the additional channels, otherwise the other channels will produce inter-modulation distortions within the receiver circuitry. The amount of distortion depends on the relative level of the signal under test compared to the power levels of other signals present. If the receiver can attenuate all incoming signals in order to bring the level of the measured channel down to an acceptable level, inter-modulation distortion will be reduced.
The measurement system 92 may use any of the following methods alone or in combinations to determine the relative level of the digital channel under test:
i) tune to each channel, measure the power, and sum the results to compute the total integrated power.
ii) measure the levels of the analog TV channels present and use the highest level as a reference. Channels at lower frequencies generally have higher levels, so only those analog TV channels up to a cutoff frequency are measured.
ii) determine a tilt line based on the levels of the analog TV channels, and measure the difference in level between the digital channel under test and the height of the tilt line at the center frequency of the digital channel.
If a separate tuner is used to measure the additional channels, the measurement subsystem 92 can update the reference level periodically. If the additional channels are measured using the same tuner 11 that the QAM receiver and measurement subsystem 92 uses, the measurement subsystem 92 takes an initial reading of the additional channels before tuning to the digital channel and commencing periodic DQI measurements. DQI updates are then suspended, and the measurements of the additional channels are repeated, if the level of the measured channel changes significantly. DQI updates may also suspend, while the additional channels are measured at some predetermined calibration interval.
Pre-FEC BER values are being updated every 5 to 50 (or 10 to 25) microseconds. In addition to averaging these values every 0.5 to 2 seconds, specific frequency components can be observed by performing a Fourier transform or by using filters.
Separate outputs can be used to measure degradation caused by two specific impairments: a component occurring at the AC power supply frequency or a multiple of it can be used to indicate the presence of hum; if the sampling rate is made fast enough, e.g. 30 microseconds or less, a frequency component of 15.75 kHz can be used to indicate the presence of composite second order (CSO) or composite triple beat (CTB) impairments.
The analysis subsystem 4 identifies times of low signal quality by time of occurrence, duration and severity. Low scores occurring within a short time period can be combined into a single impairment incident, and a weighted average can be used to represent the single impairment incident. A concise summary of significant results, e.g. high DQI score, low DQI score, average DQI score, weighted average DQI score, can be determined by the analysis subsystem 4 , when DQI measurements are acquired over a long time period.
With the aforementioned enhancements, the SNR-corner combiners may be moved from the measurement subsystem 92 to the scoring subsystem 93 , which enables the scoring subsystem 93 to output separate scores from each model or analyzer, as well as include their effects in the composite score. Separate scores can be output for specific impairment types:
DQI Component
Score
Supporting Measurement
Thermal noise
SNR analyzer, continuously low values
Impulse noise
SNR analyzer, occasional low values
CSO and CTB
SNR analyzer, 15.75 kHz frequency component
Phase noise
I-Q Corner model
Hum
Level fluctuations at multiples of the AC
power supply frequency;
SNR analyzer, components at these frequencies.
Signal level
Other level fluctuations, such as caused by
instability
amplifier AGC problems
Linear
Equalizer tap values
distortions
Intermodulation
Digital channel level too low relative to the
reference level
With the enhancements, the scoring subsystem 92 may model the performance of consumer-grade QAM receivers, and use a single model, or different parameters to model the effects of specific types or makes of receivers. The parameters that could vary with the receiver type may include but are not limited to the following:
1) The amount of variation in the input signal level that is acceptable. 2) The rate of change of the input signal level that is acceptable. 3) The percent hum that is acceptable. 4) The number of FFE and DFE taps being used in the adaptive equalizer. 5) The equalizer adaptation algorithms and parameters. 6) The sensitivity of the receiver to inter-modulation distortions. 7) The AGC bandwidth. 8) The derotator bandwidth. 9) The characteristics of any bandpass or notch filter components that may be present.
The analysis subsystem 94 can track specific types of impairments using the component DQI scores, i.e. log the time of occurrence of impairments by impairment type as well as by severity and duration.
In the display subsystem 5 , the DQI signal quality scores are reported numerically at readout 91 , e.g. updated every 0.5 to 2 seconds, and graphically over time at display readout 92 . If a specific impairment exists in the network under test, the graphical display 92 will capture a signature of the impairment. However less than 0.5 seconds and greater than 2 seconds is also possible if faster hardware is available or a slower transition is desirable. The lowest and highest DQI scores can also be displayed for a test run over a desired time period. A marker can be included in the display subsystem 95 , whereby the individual component scores at the marker position can be displayed numerically. Alternatively, the impairment type receiving the lowest component score can be displayed textually. The marker can be moved a single point at a time with individual inputs, e.g. touch pad or keyboard 26 , or it can be made to jump from one low point in the history to another. The display subsystems 5 and 95 can also show the status and results of other measurements occurring concurrently, e.g. signal level, MER, QAM lock status, and Interleaver depth. A written indication of how the system performed, e.g. pass/fail, excellent/good/fair/poor/no-signal, no-impairments/slight/moderate/severe, can also be displayed. The impairment incidents can be listed in order of occurrence or severity, along with their time and duration.
The DQI system provides more measurable data points than conventional BER systems, and responds faster to changing conditions. Impairments are reported before bit errors actually occur, without having to fully decode the incoming signals. | The present invention relates to a system for calculating a digital quality index (DQI), which provides a rating on a predetermined scale, indicative of the impairments in a received quadrature amplitude modulated (QAM) signal in a CATV cable system. The DQI system utilizes bit error rates prior to and after forward error correction to calculate the DQI value. To increase the calculation rate, the bit error rates can be estimated using voltage errors, signal to noise ratios and/or average corner error metrics. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of pending International patent application PCT/IB2006/001381 filed on Jul. 11, 2006 which designates the United States and the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to life cycle management systems. More specifically, this invention relates to a life cycle management system (LCMS) that allows location-independent control of a plurality of devices within a process plant, by integrating information from asset monitors within the plant and all stages in the life cycle of the Intelligent Electronic Device.
BACKGROUND OF THE INVENTION
[0003] The life cycle of any Intelligent Electronic Device (IED), also referred to as an asset, includes all the activities that start with design and engineering phases of the process plant application needing the device, going on to selecting a manufacturer and device to suit the application, the procurement and placement of the device into service, operating the device while it is deployed and culminating in retirement of the device from service. In the operational phase, the device is also managed and maintained to provide sustained and reliable service.
[0004] IEDs provide services to Process Industries, Discrete Component Manufacturing Industries, Power Generation, Transmission and Distribution Utilities etc. Amongst the various stages in the life cycle of an IED, there exists a variety of device management and maintenance operations performed by process plant personnel and device vendors. The device vendors perform support of disparate devices using a diverse array of tools and systems, rendering great complexity to the overall operations within the plant.
[0005] The complexity of today's systems stems from a variety of field bus standards, a number of diagnostic and maintenance tools for device management, backward compatibility requirements for several software versions necessitated in order to protect one's investment over time, several software versions of host application standards and the introduction of the Internet. For example, disparate industry standards for field bus networks in typical manufacturing plants could be any of ProfiBus, Device Net, Foundation Field Bus (for the Process Industries), Inter Bus S, Control Net and CAN Open (for the Discrete Manufacturing Industries). HART protocols need inclusion in this list even though they are not field bus protocols, as they present the same requirements towards a holistic LCMS. The disparate protocols mentioned have individual engineering tools to configure, install, commission and maintain devices that are connected using those protocols.
[0006] Field bus networks have evolved over the last ten years and many of them remain viable for many more years to come. Customers are keen to protect the investment they have made on these devices and networks, consequently being required to maintain diverse engineering tools and skills to keep the overall system running. Simply reducing the number of allied standards does not readily translate to reduced complexity. In other words, a LCMS needs to consider and make provisions for obsolete standards in a consistent manner.
[0007] At the present time, the players involved in the different stages in the life cycle of the devices in a process plant and the overall system in that plant are the design engineers, the device vendors offering support to the devices deployed, the control operator controlling the overall operation of the plant etc. The device vendors presently provide Electronic Device Description (EDD) source files written using the Electronic Device Description Language (EDDL) to standardize a simple operator control interface. This technology does not address the problems that the customer faces in coping with a diversity of vendor specific engineering tools to set up, configure, install, commission and perform the life cycle management of devices. The newer technology of Field Device Tool (FDT) and Device Type Manager (DTM), intended as an extension of the EDDL technology, has addressed this issue. This technology made it possible to have a common interface at the host systems to engineer and operate the field device networks with the field devices supplied by different vendors. This technology consequently increased the need for a LCMS owing to the large number software components, each having related and independent updates and upgrades, with respect to the host platform. Device vendors are often reluctant to shoulder the responsibility of providing DTMs for the devices which they supply, owing to the disparity in host platforms, changing software version releases for the underlying Operating Systems etc. Ethernet is now popular in process plant environments, and is rapidly evolving to accommodate an application subset that extends beyond hard real-time applications. This has further complicated the scenario. The emerging standards of ProfiNet, Ethernet IP and Ethernet for Control and Automation Technology (ECAT) are also responsible for introducing even more field devices. FDT/DTM tools are commonly unavailable for these devices utilizing the above-mentioned standards of ProfiNet, Ethernet IP and ECAT. Further, when there is a need to deploy EDDL and FDT/DTM technology concurrently, the complexity of the system increases further.
[0008] With the Internet enabling greater access with respect to Engineering and Asset Management systems, which provide thin client applications, the need for synchronization and inter-operability with the core system is amplified. Furthermore, device vendors provide several remote services and a multitude of web library servers (for different bus protocols such as PNO, ProfiBus, HART etc.), also enabled by the Internet. The design paradigm is rapidly evolving towards increasing the role of the Internet in basic connectivity of devices and other operations on devices.
[0009] Several Computerized Maintenance Management System (CMMS) packages (also known as Common Asset Management or Engineering Systems) are available for plant operators to choose from including IFCS, Maximo and SAP. These systems focus on Enterprise Application Integration and have limitations when it comes to integrating diagnostic information from devices deployed in the field.
[0010] Plant operators have available to them a variety of desktop tools, hand-held devices and commercially available Personal Data Assistants (PDAs) to enable them to receive and analyze information pertaining to the devices in the plant. These tools and mobile devices encourage the engagement of web servers to relay the information enabling location-independence when it comes to managing the life cycle of the system.
[0011] Common Asset Management or Engineering Systems referred to above have diverse customer interfaces for gathering such information, but do not have common Human Man-Machine Interfaces (HMMIs) for life cycle management information. This is because life cycle management implies control over a larger subset of tasks (including engineering design and documentation) having to do with field devices, as opposed to the CMMS or Common Asset Management or Engineering Systems.
[0012] It is a major shortcoming of the existing systems to address the complexity introduced by the disparity in protocols, tools, implementation platforms, software versions and network configurations.
[0013] PCT Patent WO 01/02953 discloses a Method of integrating an application in a computerized system, presenting a system for computerized control of a real world object, making allowances for interlinking objects systematically. This patent introduces the concept of Composite Objects, containing Aspects representing facets of real world objects. This concept of Aspects is utilized in the present invention, however, the present invention extends beyond systematic representation and computerized control, to providing a LCMS in the case of process plants. Incorporating information from several stages in the life cycle of a device is not explored in the PCT Patent, it only provides a mechanism to enable such incorporation. The LCMS proposed by the present invention is located on the control network to manage IEDs in such domains as Process Automation and Manufacturing Automation. The means for maintaining information for a device or product through its various life cycle stages is enabled by the concept of Aspect Views of real world objects, from several different perspectives, each perspective being defined as a piece of information and set of functions to create, access, and manipulate the information provided. These Aspect Views are the building blocks of the Device Integration Aspect Objects.
[0014] U.S. Pat. No. 6,795,798 discloses a method for the Remote Analysis of process control plant data. This patent does not mention incorporating the documentation aspects within its design. Further, the central method of communication in the preferred embodiment uses XML.
SUMMARY OF THE INVENTION
[0015] It is an object of this invention to provide a Life Cycle Management System that incorporates, utilizes and relays information in the engineering, installation/commissioning and operational phases of IEDs commonly used in process plants. Another object of this invention is to address the complexity in a highly distributed control environment. This is achieved using a combination of compatibility checks and version control checks, allowing customer-interactivity where desired and relevant. Another object of this invention is to use information aggregated in Device Integration Aspect Objects, organized by different Aspects pertaining to the life cycle of an IED in conjunction with information obtained from asset monitors in various physical process plants, serviced by the LCMS, to provide asset optimization within the process plants. Further, this invention seeks to provide such control and optimization in a location-independent fashion, making provisions for such distributed environments as enabled by the Internet. Device vendors can connect to the information made available by the LCMS in order to provide diagnostic support, without being physically present at the plant site.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 provides an overview of the LCMS framework.
[0017] FIG. 2 shows the layout of an industrial plant
[0018] FIG. 3 shows a modular overview of the various components in a Life Cycle Management System.
[0019] FIG. 4 shows the stages in the Life Cycle of a device.
[0020] FIG. 5 shows the details maintained in a Device Integration Aspect Object.
[0021] FIG. 6 shows an Automation Object, also referred to as a Device Integration Aspect Object.
[0022] FIG. 7 expands on the Documentation Aspect.
[0023] FIG. 8 shows another feature of the LCMS, which involves version checking the overall system.
[0024] FIG. 9 shows the bi-directional data exchange between the process engineering environment and the control system engineering environment.
[0025] FIG. 10 shows the Asset Monitor Report, used to communicate device information.
[0026] FIG. 11 shows the Asset Monitor status reports.
[0027] FIG. 12 shows the Asset Condition Report.
[0028] FIG. 13 shows the integration of the Internet in the process control systems.
[0029] FIG. 14 shows the connectivity application provided to the vendor to enable location-independent diagnostics.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The Life Cycle Management System of the present invention incorporates, utilizes and relays information in the engineering, installation/commissioning and operational phases of IEDs commonly used in process plants. Complexity in process plants are introduced by the diversity in field bus networks, network protocols, a number of diagnostic and maintenance tools for IED management, backward compatibility requirements for several software versions necessitated in order to protect one's investment over time, several software versions of host application standards and the introduction of the Internet.
[0031] FIG. 1 provides an overview of the LCMS framework. The LCMS integrates standards such as the DD/EDD/CFI/TEDS store 1 , DTM Builder 2 , DTM Inspector 3 , Device communication FDTs 4 connected to several DTMs 5 . It further integrates various control technologies, for example, the Human Machine Interface (HMI) 6 , document managers 7 , control function designers 8 , field bus topology builder 9 , device management 10 , Asset Monitoring/optimization 11 and device integration package installation tool 12 . The interactions and data-flow between the modules detailed above are recorded and controlled by using a database server 13 , a data store 14 , a plurality of device connectors 15 , control connectors 16 and network connectors 17 , an Asset Management server 18 , a proxy server 19 (when required), and a web server 20 (when required).
[0032] FIG. 2 shows the layout of a process plant 38 , connected to a Life Cycle Management System 25 . Within the process plant, there exists a number of sensor networks and smart transducers 30 and Field Devices, connected by networks such as Multiplexed EtherNet 31 , a HART signal bus 32 , ProfiBus 33 , ProfiNet 34 , CAN Bus 35 , InterBus S 36 and ASI Bus 37 . There exist one or a plurality of Operator Work Stations 26 which overlook the operations of the IEDs and networks. These networks, connecting the various IEDs, sensors, transducers etc., communicate with an IED Gateway 29 which in conjunction with a Network Communication Application Processor 28 , collects data from all the devices and relays them to the Life Cycle Management System 25 . The Life Cycle Management System 25 , communicates with a variety of external systems such as, Computer Based Management Stations 23 , Device Vendor Remote Service Stations 22 , Web Library Servers 21 providing updates for various IEDs and control networks via the Internet and an array of mobile devices 27 which can be sent information for remote control and maintenance of the plant by an operator.
[0033] The stages in the life cycle of an IED include an engineering phase, an installation/commissioning phase and an operational phase. These phases have several sub-phases within them. In the Engineering Phase the actual design is carried out and relevant documentation is generated and collected, for future reference. Further, there exist several engineering sub-systems that need to be taken into account such as document managers for document administration, library assistants, reuse assistants, cross-reference tools and document import/export capabilities. In the Installation/commissioning Phase the physical location of the IED in the plant is defined in the drawings pertaining to layout of the IEDs in the plant. In addition, a set of drawings are made to define the installation/commissioning of the IED, its connection to the process on one end and on the other to the equipment in the control room via bus architectures, with details of installation/commissioning hardware (hubs/drop cables/couplers/power supply units). In the Operational Phase, several functions such as maintenance, performance monitoring etc. are carried out. In this phase, the Device Management System and the Computerized Maintenance Management Systems are treated as extensions to an Asset Management System that monitors the health of IEDs, generates the Asset Condition Report and alerts the concerned plant personnel. FIG. 4 shows the stages in the Life Cycle of an IED including the Engineering Phase 47 , the Installation Phase 48 and the Operational Phase 49 . The information pertaining to the state of the IED or assets from the various phases is aggregated into what are termed Aspects, which are the building block for Device Integration Aspect Objects. The different Device Integration Aspect Objects are populated with information from the various life cycle phases and do not correspond to information from a single or a set of life cycle phases. Examples of Aspects within this object include the Definition Aspect, the Documentation Aspect, the Diagnostics Aspect and the Configuration Aspect.
[0034] FIG. 5 shows the details maintained in a Device Integration Aspect Object, which is used to aggregate information from various stages in the life cycle of the IED. The Aspects represented in this object include the Field Device/Sensor definition Aspect 50 , the Field Bus/Sensor Network Management Aspect 51 , the Device/Sensor Health Monitoring and Diagnostics Aspect 52 and the Documentation Aspect 53 .
[0035] FIG. 6 shows an Automation Object 54 , also referred to as a Device Integration Aspect Object 55 . The Device Integration Aspect Object aggregates information having to do with the IED, arranged in terms of Aspects. In this figure, special emphasis is placed on the Documentation Aspect. Documentation about an IED may come from various life cycle stages. For example, the engineering phase could include design documentation such as circuit diagrams 58 . The installation phase might benefit from data sheets 57 . The operational phase might use measurement information 59 and maintenance data 56 . Even though this documentation might be present in different formats, the LCMS of the present invention makes provisions for storing these different formats and converting across formats, when necessary.
[0036] FIG. 7 expands on this Documentation Aspect further by presenting the means in which one subset of the LCMS, the Asset Management function maintains documentation 61 and displays it 62 for one particular IED 60 .
[0037] The present invention has the means for creating Device Integration Aspect Objects to represent real world IEDs from several different perspectives, each perspective being defined as a piece of information. A set of functions to create, access, and manipulate the information is also provided. These different perspectives on a real world object are optionally represented by software applications, which are partly provided by the system vendor. An increasing amount of such software applications are provided by device manufacturers or third party companies, who provide add-on-applications like calibration management or CMMS functionalities. It is desirable to be able to integrate such software without changing the way these applications work internally, whereby it is not reasonable to require that all different applications are aware of each other.
[0038] Examples of device specific components and functions are:
installation/commissioning of device specific Device Type Manager Configuration, commissioning and diagnosis Access to device specific engineering documentation Connectivity to Asset Monitoring and Asset Management System Connectivity to Device Management System Connectivity to Remote Computerized Maintenance Management system.
[0045] The LCMS uses the information aggregated in Device Integration Aspect Objects along with information obtained from local Asset Monitors located in the physical process plants, to perform Asset Optimization for IEDs. Since the Device Integration Aspect Objects contain several pieces of relevant information such as engineering documentation, maintenance data, data sheets pertaining to the individual devices etc., the LCMS is able to perform holistic management and optimization, to enhance the life of the IEDs deployed in the field. For example, if an IED encounters a problem, this is reported to the LCMS by the Asset Monitor in the plant. The LCMS goes on to look up the pertinent design documentation that has an answer to the problem. Further, the LCMS might send this error condition to a remote device-vendor, who can send the solution back to the LCMS. This way, the life of the asset is enhanced since a multitude of information and diagnostic support is made available to correct whatever operational challenges the IED/asset may face in it's lifetime.
[0046] FIG. 3 shows a modular overview of the various components in a Life Cycle Management System. Utilizing data 300 stored in Device Integration Aspect Objects 301 , and information from various asset or device monitors 302 in one or several physical plants 303 , 304 , 305 , 306 , 307 , each having their own individual configurations, Operating System platforms and maintenance software, the LCMS 25 , performs Asset Management and optimizes the life of the assets in a process plant. It further provides a location-independent design to provide such control and management/optimization functionality by means of connectivity applications, which are used as conduits to communicate information, over such distributed network configurations such as the Internet. Such communication can occur between the customer, whose physical process plants 303 , 304 , 305 , 306 , 307 , the LCMS of the present invention is controlling. This multitude of process plants indicates the LCMS using a clustered and scalable strategy and demonstrates its use and applicability in a large processing complex. Subsequently, when necessary, connectivity applications 308 , 309 can be used to communicate error information with device vendors or to communicate with any of other CMMS systems or Web Library Servers, which provide updates for various network protocols etc. Further, the LCMS is able to communicate with device vendors, by means of connectivity applications 310 , 311 , in order to facilitate location-independent debugging or error diagnostics. The LCMS employs one or a plurality of servers 312 , 313 , 314 to carry out Asset Management along with a data store or a plurality of data stores 315 , 316 , 317 . The data store could optionally use a Redundant Array of Independent Disks, for better availability. The information that is communicated between the different modules is secured by known authentication means. Optionally, the information is accessible by authenticated parties with the use of the Simple Object Access Protocol, or any other markup language 310 , 311 .
[0047] A two way communication has to occur between the process plant ( 303 - 307 in FIG. 3) and 38 in FIG. 2 ) and the control system engineering environment, placed within the LCMS. The communication provides means for the exchangeability of process data, like limits, alarm values or units, between the IEDs and Control module logic and function block structures, within the LCMS, confirming to, IEC-61149, IEC61131-3 and IEC 61804-2. FIG. 9 shows the bi-directional data exchange between the process engineering environment (PEE) 90 and the control system engineering environment (CSEE) 91 residing within the LCMS. From this exchange we see that the system is configured or initialized 92 with the creation of Device Integration Aspect Objects through an exchange of information between the PEE and the CSEE. Furthermore, the health of the IED is communicated from the control system to the process engineering environment 93 . The LCMS has means to enable this exchange while making provisions for various document formats.
[0048] The IED information is communicated through the Asset Monitor Reports 100 , shown in FIG. 10 . They contain a plurality of information such as the severity of the condition 102 , the condition itself 103 , the sub-condition 104 , the description of the condition 105 , the timestamp associated with the condition 106 and the quality status 107 .
[0049] FIG. 11 shows the Asset Monitor status reports. The HART generic device Asset Monitor 113 in this case was found to have a good status 115 , have its details about the last execution 116 , and the last time it was started 117 , with the execution statistics 118 , the execution interval 119 and the asset parameters 120 , being shown in the Asset Monitor Status 121 . Every device has only the set of information relevant to it being shown. For example, the Asset Monitor for the ABB Generic HART Device 121 , has only a status field 122 , a Logic field 123 , an execution statistics field 124 and a startup configuration field 125 .
[0050] FIG. 12 shows the Asset Condition Report generated by the LCMS. The asset's condition details 126 , are communicated by means of detailing the exact condition or sub-condition 127 , a time-stamp recording when the condition took place 128 , the severity of the condition 129 , a description of the condition 130 , the possible cause of the condition 131 , the suggested action 132 , and a log of the corrective action taken 133 .
[0051] FIG. 10-FIG . 12 also demonstrate the homogeneous visual handling and navigation means for accessing Device Integration Aspect Objects and their aspects in Plant/Functional/Location Structures, within the LCMS.
[0052] The LCMS generates an Asset Condition Report and advises the vendor standard predictive maintenance service actions, extending the on-stream availability of IED. Such information can be send via the Internet to any web client or to customer devices such as mobile phones, e-mail accounts and pagers. Further, the LCMS provides connectivity to the third party systems for Device Management and Computerized Maintenance Management Systems.
[0053] In current practice, device vendors provide several remote services and a multitude of web library servers (for different bus protocols such as PNO, ProfiBus, FIART etc.), also enabled by the Internet. The design paradigm is rapidly evolving towards increasing the role of the Internet in basic connectivity of devices and other operations on devices. The LCMS of the present invention takes this design paradigm into consideration and makes provisions for it.
[0054] FIG. 13 shows the integration of the Internet in the process control systems. DTMs are popularly made available by vendors online and device specific DTMs can be downloaded 136 when the customer wants to perform device management 135 .
[0055] The LCMS of the present invention ensures that only the libraries that have passed the check for version compatibility are imported. As the import of objects from the library for the installation/commissioning and application integration functionalities can be rejected, for example, due to version incompatibility, unknown origin, invalid or outdated certifications, etc customers do not have the risk of getting stuck midway in the installation/commissioning process or having face problems in restoring the status-ante. However, a device and its according software cannot be seen as a single entity. Hence, the LCMS has a much wider focus and includes version checks for the operating system or for control system applications like the Control Function Designer, which is used to graphically build the control logic. Hereby the LCMS also considers the customer's inputs, for example whether the installation/commissioning needs to be conform to IEC 61131-3 or IEC-61804-2 standards and assigns the according documentation. The advantage for the customer is that the system is ready for use, directly after the installation/commissioning and without any further regression tests. This methodology reduces the down time incurred for updates significantly.
[0056] FIG. 8 shows another feature of the LCMS, which involves version checking the overall system 71 , before downloading/upgrading or updating the system in any way. Updates can be made available for a plurality of IEDs or networks 70 and means exist to log the results of the version checking 73 and controlling what is finally installed or rejected 72 .
[0057] The LCMS of the present invention seeks to provide control and optimization in a location-independent fashion, making provisions for such distributed environments as enabled by the Internet.
[0058] Plant operators have available to them a variety of desktop tools, hand-held devices and commercially available Personal Data Assistants (PDAs) to enable them to receive and analyze information pertaining to the IEDs in the plant. The LCMS of the present invention is capable of sending information, having to do with the life cycle of any IED within the plant, to a plant operator, via the Internet. The information is communicated by means of a connectivity application. This connectivity application is provided by the LCMS to ensure at any time that the local applications are in sync with the core system. However, the asset conditions can be checked locally via any standard web browser or customer device as described above.
[0059] The benefit of this approach is that the customer can observe and maintain DDEs locally without the need of a full-blown Control or Asset Optimization or Life Cycle Management system that is physically co-located with the process plant. That means the customer has the full asset management functionality as described above without the initial investment for a local control system and without the ongoing maintenance costs for system updates or version management as described in the first part of the invention disclosure.
[0060] Another advantage of this architecture is that it allows involvement of the device vendor during error diagnosis without the requirement of being on site. Therefore, the vendor simply downloads the connectivity application and can simulate any error condition at another site, to reproduce problems on customer site and will get the according response from the Asset Management Server. This implies that device vendors will have very lean and cost efficient approach for customer specific maintenance. Device vendors can connect to the information made available by the LCMS in order to provide diagnostic support, without being physically present at the plant site.
[0061] The vendor's diagnostic sub-system 140 , shown in FIG. 14 just downloads the connectivity application 141 over the Internet 143 and can simulate any error condition at his lab 142 to reproduce problems on customer site and will get the according response from the LCMS 25 . That means that device vendors will have very lean and cost efficient approach for customer specific maintenance. | This invention relates to the Life Cycle Management System for distributed Intelligent Electronic Devices (IED) starting from the design phase to the end of service phase. Hence, it caters to the needs from installation via engineering, installation/commissioning phases, until asset management and remote service support of the devices during the operational phase The increasing decentralization of the involved components via networks, especially via the Internet, is a key criterion and needs to be addressed by the life cycle management. The added value for the customer grows disproportionately with the degree of integration of multiple independent software components into a complex and often highly distributed control system. The architecture of today's control systems must be sufficiently flexible to allow customers to regard their plant components from various locations. Additionally, the stability, security and maintainability of such a system is strongly dependent on the homogeneity and interoperability of all involved components. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to the coupling of data word transfer devices in computer systems, in particular the coupling of different-speed bus systems.
Two bus systems operating at different data rates can be coupled via memory modules called FIFOs, for example the Type 74ALS2233 from Texas Instruments. These modules have a memory with two access paths via which, simultaneously, a transmitter can store data and a receiver can read data. Counters contained in the module are used to output the data in the sequence in which it is stored. In this case, the module provides signals which indicate that the input section is full and that the output section is empty. The former signal is used to stop the transmitter if the receiver has not been able to receive the data sufficiently quickly. The second signal causes the receiver to accept the data. If the transmitter is transmitting the data words in packets in which the data words follow one another more quickly than the receiver can process them, but there is a relatively long pause between data packets from the transmitter, then the receiver can process the data at a medium speed. If the receiver has a higher acceptance rate than the transmitter, a filling level signal for, for example, half-full, is frequently provided. Only when the buffer store is half-full is the receiver started for acceptance, and then accepts data until the buffer store has become empty. In this case, the transmitter and receiver frequently operate in the asynchronous mode, in which the transmitter transmits at times that are not predetermined and the receiver allows a variable length pause between two data words.
In computer systems and, in particular, in the case of access to bus systems, arrangements are used in which data packets comprising a predetermined number of data words are transmitted without interruption, also called the synchronous mode. The FIFO buffer stores mentioned above are also used if the clock rates of the transmitter and receiver differ.
A known application of FIFO memories in synchronous bus systems comprises the entire data packet initially being stored in the buffer store, with the transfer to the receiver being initiated at the end of the data packet, once all the data words are in the memory. However, the transmission rate of this arrangement is considerably less than that of the transmitter or receiver. Because of the synchronous operating mode, in contrast to the asynchronous operating mode, the transmission to the receiver (the data sink) cannot take place until it is certain that the data packet can be sent without interruption. This is undoubtedly the case once the data source has completed the transmission process. The loss of bandwidth in the case of this simple method thus corresponds to the duration of data transmission on the faster bus.
An improvement can be achieved if the outputting to the receiver has already started even though the transmitter has not yet transmitted all the data. Since the transmitter transmits continuously, it is possible to determine in advance, for a predetermined transmission and reception clock rate, the buffer store filling level beyond which the transmission to the receiver can be started. The calculation of the filling level in this case has to assume the worst-case boundary conditions, that is to say, if the transmitter is slow in comparison with the receiver, the slowest input clock rate and the fastest output clock rate. If the input clock rate is higher than the assumed slowest input clock rate, then the output to the receiver starts later than the optimum time. This results in lost waiting time or a delay for the transmitter between two data packets.
For example, if a central processor unit is being operated on a peripheral bus, the clock rate on the bus from the transmitter can be changed. The buffer store must then be designed for the slowest peripheral, as a result of which faster peripherals cannot achieve the maximum data packet repetition frequency and are thus not connected optimally.
European Patent Specification EP 0 247 317 specifies a method for coupling a fast channel to a slow channel, in which the data transfer starts when a threshold value is reached which is set on the basis of previous transfers.
SUMMARY OF THE INVENTION
The object of the invention is thus to operate a buffer store in systems where data packets are transmitted continuously, such that virtually delay-free transmission is achieved even if the clock rates differ.
The invention uses a measurement and calculation circuit in which the output clock rate is related to the input clock rate, and a start value in output clock cycles is determined in this way. To this end, the number of output clock cycles during a known number of input clock cycles is determined, is divided by the number of data packets corresponding to the number of input clock cycles, one is added and the data packet length is subtracted. The resultant value represents the number of output clock cycles which must pass after the start of transmission before transmission to the receiver can start.
The invention is thus a method and an arrangement for buffering between two synchronously clocked devices which transmit and receive data packets of data words, the output being enabled as soon as the number of output clock cycles after the start of a data packet exceeds a start value which is determined in advance by measuring the output clock cycles as a function of the input clock cycles.
In the preferred application, the number of data words per packet and the number of measured input clock cycles are in this case a power of two, as a result of which the multiplications and divisions can be achieved by circuitry, and can be achieved easily even with highspeed bus systems.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel, are set forth with particularity in the appended claims. The invention, together with further objects and advantages, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several Figures of which like reference numerals identify like elements, and in which:
FIG. 1 shows a circuit for coupling a data source to a data sink,
FIG. 2 shows a signal diagram for data transfer using the circuit according to FIG. 1,
FIG. 3 shows a signal diagram for determining the start value with the circuit according to FIG. 1,
FIG. 4 shows a signal diagram for data transfer using the circuit according to FIG. 1 in accordance with the invention,
FIG. 5 shows an alternative circuit for part of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a circuit for transmitting data packets between two bus systems. A data source, which is not illustrated for the sake of clarity, uses a bus system 10 with a source data line section 11 (SDa) and associated control lines 12 (SCn). The data sink likewise uses a bus system 10' with data lines 11' (RDa) and control lines 12' (RCn). A buffer store 15 (FIFO) of a known type, for example Type 74ALS2233 from Texas Instruments, is connected both to the source data lines 11 and to the destination data lines 11'. The signals on the control lines 12 are used by a drive circuit 16 to produce a signal for the buffer store 15, this signal being applied to the acceptance input W of said buffer store 15, and signals for the control circuit 13, which are described in more detail further below. A further drive circuit 16' produces the acceptance signal for reading from the buffer store 15, and is thus connected to its input R. At the same time, it produces the bus control signals for the control lines 12' of the bus system 10' for the data sink.
In the following text, it will always be assumed that the bus systems operate synchronously, to the extent that the clock signals are present uniformly and continuously. It is furthermore assumed that the data transmission takes place in packets, and thus that a plurality of data words are produced with successive clock signals of the bus systems, said data words having a number of bits which does not exceed the number of data lines. In this case, as a rule, the clock signals of the bus systems are neither at the same frequency nor do they have a fixed mutual phase relationship, and it is necessary to take account of this when interpreting the figures.
Optimal operation of this bus coupling arrangement is illustrated in FIG. 2, the assumption being made that the transmitter is slower than the receiver. The clock signals 12 (SCn), which also determine the transmission clock ClockIn, are used to confirm that a data packet of four data words D0, D1, D2, D3 is to be transmitted at the time t 1 , this being indicated by the signal ValidIn. The data words are transferred into the buffer store with the four immediately following clock cycles. The signal DataIn represents the data on the bus 10 of the data source, and the signal INPREG represents the data in the buffer store FIFO. Ideally, the data transfer to the data sink does not start until the time t 2 , which is chosen to be sufficiently late that both data transfers are completed at the time t 3 . The signal ClockOut represents the clock, the signal Validout the control signal and the signal OutReg the data on the bus 10' of the data sink.
The measurement to determine the optimum starting time is illustrated in FIG. 3. The signal ClockIn once again represents the clock on the bus of the data source which, because operation is synchronous, is present continuously without any data transfer taking place in this case. The bus is thus already in the synchronous mode, in which the clock ClockIn occurs at equidistant time intervals and the frequency is that at which the subsequent data transfers will also take place. If the clock rates are changing, the controller 13 thus internally produces a signal which represents the synchronized state of the bus 10, and is not illustrated. A measurement signal TestSig is now produced from this signal, is synchronized to the input clock ClockIn and lasts for a predetermined number n of clock pulses. In principle, this number n is freely variable; however, the following steps can be implemented more easily if it is a multiple of the number of data words per data packet. This number of data words per data packet can on the one hand be determined during the design phase of the computer system, during which it is generally possible to tell which data packets will occur frequently. It can also be determined dynamically during operation. If more than one packet length can be expected, the lowest common multiple can also expediently be used as the multiple. In the majority of computers, the data packet length is a power of two. A suitable value for the number n is thus 8 or 16.
During the time of the measurement signal TestSig, which time is determined by the number n, the number of clock cycles on the receive bus 10' are counted. The signal TestSig thus represents the enable signal for a counter whose count input is connected to the clock signal of the bus 10' of the data sink. In the example in FIG. 3, a number n=8 was chosen and a number c=12 of clock cycles were counted on the receive bus 10', represented by the signal SpeedCnt in FIG. 3.
In a first embodiment, the number obtained in this way is divided directly by the number of data packets per measurement interval, in the example in FIG. 2, this is the number 8 divided by 4 equal to 2; in the example, this gives the number 6. The division with truncation by 2 can be carried out in a known simple manner by circuitry. In order to compensate for the error caused by the phase difference between the two bus clocks, this number is also incremented by one. Greater summands are possible, but in general are not optimum. This increased number, in the example the number 7, is then stored in a resister. The measurement can also initially be unchanged in a register, and can later be divided by the number of clock cycles per data block and incremented by one, if different block sizes can occur with the clock rate unchanged.
A data transfer following the described measurement phase is illustrated in FIG. 4. The start of transmission, that is to say of the data transfer on the input bus 10, is represented by the activation of the signal ValidIn. The next-but-one output clock pulse transfers the signal ValidIn and thus produces the signal Count which enables a counter which counts the number of clock cycles on the bus 10 for the data sink. Once this counter 17 has reached the determined delay value x, which has been determined in advance as the difference between the value determined in the measurement phase according to FIG. 2 and the number of data words per data block to be transmitted, the signal ValidOut is produced and causes the data to be transmitted from the buffer store 15, by means of the bus 10', to the data sink.
FIG. 5 shows an alternative circuit for producing the waiting time between the start of transmission by the transmitter (t1) and the start of transmission to the receiver (t2). In this case, the counter 17 is replaced by a step-down counter 46 and the comparison 18 by a comparison 18' of the status of the step-down counter 46 with the number of data words per data block, this number being stored in a register 43. First of all, in the same way as until now, the number n of clock cycles preset for the measurement (register 42) on the bus 10 of the data source is divided by the number b of data words per data block (register 43). If the latter is a power of 2, then the division is carried out by a multiplexer which acts as a shift register. Otherwise, with the small number of questionable numbers, division can also be carried out by addressing a read only memory in which the dividend and divisor together represent the address of the read only memory, and the stored data word outputs the quotient, if necessary rounded. This quotient n/b obtained in this way is used as the divisor for a second division, in which the measured number c (register 41) is divided by the quotient n/b. Once again, a multiplexer or a read only memory must be provided, depending on the boundary conditions. The quotient is incremented by one. This result, which is called SpeedValue in FIG. 2, is now loaded directly into the step-down counter 46 which, when the transfer from the data source starts, is decremented by the clock of the other, namely the bus of the data sink. The count is compared with the number of data words per data block. As long as the count is greater, the transfer to the data sink remains inhibited. If it is equal or less, the transfer to the data sink is enabled. It is then irrelevant whether this transfer starts immediately or is still delayed because of a blockage at the data sink. This arrangement in any case ensures that the earliest time from which the data transfer to the data sink is possible is determined safely and is close to the optimum value, even at high bus speeds.
A technically equivalent option to the addition of the constant 1 after the division is to preload the counter with the divisor or the divisor
The invention is not limited to the particular details of the method and apparatus depicted and other modifications and applications are contemplated. Certain other changes may be made in the above described method and apparatus without departing from the true spirit and scope of the invention herein involved. It is intended, therefore, that the subject matter in the above depiction shall be interpreted as illustrative and not in a limiting sense. | Method and arrangement for buffering between two synchronously pulsed devices which transmit and receive data packets of data words, the output being enabled as soon as the number of output clock cycles after the start of a data packet exceeds a start value which is determined in advance by measuring the output clock cycles as a function of the input clock cycles. | 6 |
RELATED APPLICATIONS
This application claims priority to and the benefit of U.S. Provisional Application Ser. No. 61/439,217, filed Feb. 3, 2011, the full disclosure of which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of Invention
The invention relates generally to the field of oil and gas production. More specifically, the present invention relates to a modular apparatus for providing communication between members of a downhole string. Yet more specifically, the present invention relates to a cartridge inserted into an end of a perforating gun equipped with a receptacle or contact at both ends for connection to a signal line through a perforating gun string.
2. Description of Prior Art
Perforating systems are used for the purpose, among others, of making hydraulic communication passages, called perforations, in wellbores drilled through earth formations so that predetermined zones of the earth formations can be hydraulically connected to the wellbore. Perforations are needed because wellbores are typically completed by coaxially inserting a pipe or casing into the wellbore. The casing is retained in the wellbore by pumping cement into the annular space between the wellbore and the casing. The cemented casing is provided in the wellbore for the specific purpose of hydraulically isolating from each other the various earth formations penetrated by the wellbore.
Perforating systems typically comprise one or more perforating guns strung together, these strings of guns can sometimes surpass a thousand feet of perforating length, but typically shorter in a wireline application. In FIG. 1 an example of a prior art perforating system 10 is shown disposed in a wellbore 12 and made up of a string of perforating guns 14 connected in series. Typically, subs 15 may connect adjacent guns to one another. The perforating system 10 is deployed from a wireline 16 that spools from a service truck 18 shown on the surface 20 . Generally, the wireline 16 provides a raising and lowering means as well as communication and control connectivity between the truck 18 and the perforating system 10 . The wireline 16 is threaded through pulleys 22 supported above the wellbore 12 . In some instances, derricks, slips and other similar systems are used in lieu of a surface truck for inserting and retrieving the perforating system into and from a wellbore. Moreover, perforating systems may also be disposed into a wellbore via tubing, drill pipe, slick line, coiled tubing, to mention a few.
Included with each perforating gun 14 are shaped charges 24 that typically include a housing, a liner, and a quantity of high explosive inserted between the liner and the housing. When the high explosive in a shaped charge 24 is detonated, the force of the detonation collapses the liner and ejects it from one end of the shaped charge 24 at very high velocity in a pattern called a “jet” 26 . The jet 26 perforates casing 28 that lines the wellbore 12 and cement 30 and creates a perforation 32 that extends into the surrounding formation 34 .
Shown in FIGS. 2A-D are sectional views of the prior art perforating gun 14 of FIG. 1 . As shown, the shaped charges 24 are typically connected to a detonating cord 36 , which when detonated creates a compressive pressure wave along its length that initiates detonation of the shaped charges 24 . A detonator 38 is typically used to set off detonation within the detonation cord 36 . In FIG. 1 , the detonator 38 is shown in a firing head 40 provided in the string of perforating guns 14 . Initiating detonation of the detonation cord 36 generally takes place by first sending an electrical signal from surface 20 to the detonator 38 via the wireline 16 . Referring back to FIGS. 2A-D , an upper connection sub 42 contains a terminal 44 for receiving signals transmitted along the wireline 16 . A signal line 46 attaches to the terminal 44 and conveys signal(s) from the wireline 16 to the remaining portions of the perforating system 10 , including the detonator 38 . Multiple connectors 48 are used to make up the signal line 46 through the successive connecting subs 15 and perforating guns 14 . The signal through the signal line 46 initiates high explosive in the detonator 38 that transfers to the attached detonation cord 36 . Detonators 38 may sometimes be provided within connecting subs 15 for transferring the detonating charge along the entire string of perforating guns 14 . Without proper continuity between the wireline 16 and detonator(s) 38 , the shaped charges 24 cannot be detonated. However, failure points in the signal line 46 are introduced with each connector 48 .
Generally the detonators are connected to the detonating cords in the field just prior to use. Thus they are shipped to the field with the electrical portions and high explosive coupled together in a single unit. Because of the risks posed by the high explosives and the threat of a transient electrical signal, shipment and storage of the detonators is highly regulated, this is especially so when being shipped to foreign locations. Additional problems may be encountered in the field when connecting detonators to the detonating cord. Perforating guns when delivered to the field generally have the shaped charges and detonating cord installed; to facilitate detonator connection some extra length of detonating cord is provided within the gun. Connecting the detonator to the detonating cord involves retrieving the free end of the detonating cord and cutting it to a desired length then connecting, usually by crimping, the detonator to the detonating cord. These final steps can be problematic during inclement weather. Additionally, these final steps fully load a perforating gun and thus pose a threat to personnel in the vicinity. Accordingly benefits may be realized by reducing shipping and storage concerns, increasing technician safety, and minimizing the time required to finalize gun assembly in the field.
SUMMARY OF INVENTION
Disclosed herein is an example of a perforating string insertable into a wellbore. In this example the perforating string is made up of a perforating gun having an upstream end with a receptacle fitting, a signal line with an end electrically connected to the receptacle fitting. Included with the example perforating string is a cartridge sub having a connector inserted into electrical connection with the receptacle fitting, a detonator in the cartridge sub and having a detonating end adjacent to and directed towards the upstream end, and a lead line in the cartridge sub having an end in selective communication with an electrical source and another end in communication with an inlet to the detonator. Optionally, the connector is an annular member that circumscribes a downstream end of the cartridge sub, and wherein the connector coaxially inserts into the receptacle fitting. In an embodiment, the perforating string further includes a switch in the lead line for selectively regulating electricity to the detonator. In this example, a ground lead is optionally included that is connected between the detonator and the switch, wherein the switch selectively communicates the ground lead to ground. In one example, the switch, the lead line, and the detonator are provided within an elongated body that coaxially inserts within an annular housing to define the cartridge sub. In one optional embodiment, further included with the perforating string is a transfer lead line having an end in selective communication with the electrical source and another end in communication with the connector for selectively providing communication between the electrical source and the signal line. A downstream cartridge sub may also optionally be included that has an inlet line in electrical communication with the signal line, an outlet lead line in communication with a bridge plug assembly, so that when an electrical signal is applied to the signal line, the electrical signal is transferred through the downstream cartridge sub to the bridge plug assembly for deploying a bridge plug in the bridge plug assembly.
Also provided herein is an example of a connector assembly for connecting an upstream perforating gun to a downstream perforating gun. In one example the connector assembly includes an annular housing, an elongated cartridge body inserted within the housing, an annular connector provided on a downstream end of the body and inserted into electrical contact with a receptacle in the downstream perforating gun, a detonator in the cartridge body for initiating a detonating cord in the perforating gun, and a lead line in the cartridge body having an end in selective communication with an electrical source and another end electrically connected to the connector. Optionally, a switch may be included in the body that is connected to the lead line and to an inlet line on the detonator. Also further Optionally included is an outline line that connects between the switch and the detonator, and a ground line that connects between the switch and ground, so that when a detonation signal and detonation current is sent to the switch, the inlet line, outlet line, and ground line form a circuit for flowing current through the detonator for initiating detonation of the detonator and the detonating cord.
An example method of perforating is provided herein that in one example includes providing a perforating gun with shaped charges, a detonation cord, a receptacle connection, and a signal line in communication with the receptacle connection. A cartridge sub is also provided that has an upstream end, a downstream end, a connector in the downstream end, and a lead line electrically connected to the connector. In the example method, the connector is connected with the signal line by inserting the downstream end of the cartridge sub into the receptacle connection, the shaped charges are detonated by providing a detonation signal to the detonator. In one example, the step of providing a detonation signal to the detonator includes directing electricity from an electrical source to an inlet line connected to the detonator. Optionally in the method, a switch is provided in the cartridge sub for providing electrical communication between the electrical source and the detonator, and for providing electrical communication between an outlet line on the detonator and ground for completing an electrical circuit through the detonator. In one example of the method, the perforating gun is a downstream perforating gun. In this example, further includes is a step of diverting some of the electricity from the electrical source through the lead line, to the connector and the receptacle for initiating detonation of shaped charges in a perforating gun downstream of the downstream perforating gun.
BRIEF DESCRIPTION OF DRAWINGS
Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a partial sectional side view of a prior art perforating system in a wellbore.
FIGS. 2A-D are side sectional views of a portion of a perforating string of FIG. 1 .
FIGS. 3 and 4 are side sectional views of a perforating system in accordance with the present disclosure.
FIG. 5 is an example of a perforating string disposed in a wellbore in accordance with the present disclosure.
While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. For the convenience in referring to the accompanying figures, directional terms are used for reference and illustration only. For example, the directional terms such as “upper”, “lower”, “above”, “below”, and the like are being used to illustrate a relational location.
It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.
In FIG. 3 an example embodiment of a perforating system 60 is shown in a side sectional view. In this example, the perforating system 60 includes perforating guns 62 1 , 62 2 each having a series of shaped charges 64 disposed within. Each perforating gun 62 1 , 62 2 further includes a detonating cord 66 disposed lengthwise therein so it is positioned proximate each of the shaped charges 64 ; thus when the detonating cord 66 is initiated, it may in turn initiate detonation of the shaped charges 64 . Initiating the detonation cords 66 forms a pressure wave that travels the length of the detonation cords 66 . In the example embodiment of FIG. 3 , the pressure wave travels in the direction of arrows A, and as will be described in more detail below, an initiation signal reaches perforating gun 62 1 before reaching perforating gun 62 2 . Thus for the purposes of reference only, perforating gun 62 1 is referred to as an “upstream” gun whereas perforating gun 62 2 is referred to as a “downstream gun”.
Coupled in series with the downstream perforating gun 62 2 is a cartridge sub 68 having a cartridge assembly 70 set within the housing of the cartridge sub 68 . In the embodiment of FIG. 3 , the cartridge assembly 70 is shown made up of an elongated body 71 , and within the body 71 are a switch assembly 72 and an optional circuit board 74 for selectively performing switching operations within the switch assembly 72 . In one example of operation, the switch assembly 72 regulates transmission therethrough of electrical signals through the switch assembly 72 that are received by an inlet lead 76 in the cartridge sub 68 from the upstream perforating gun 62 1 . The switch assembly 72 also includes a ground lead 78 on the side with the inlet lead 76 ; the ground lead 78 is selectively in electrical communication with the switch assembly 72 such as by the switching action provided by the circuit board 74 . Exiting the switch assembly 72 , on a side opposite the inlet lead 76 , is a supply lead 80 that is in electrical communication with a communication line 82 shown extending within the downstream perforating gun 62 2 . In an example embodiment, inlet lead 76 selectively couples with an electrical source for receiving electricity. Also exiting the switch assembly 72 are a signal lead 84 and a ground lead 86 . In an example, the leads 84 , 86 make up a detonator connection that provides selective electrical communication between the signal assembly 72 and a detonator 88 shown set in an end of the cartridge assembly 70 adjacent the downstream perforating gun 62 2 . As illustrated in FIG. 3 , the modular cartridge assembly 70 can be inserted within the annular cartridge sub 68 for easy assembly and removed from within the cartridge sub 68 for replacement and/or repair.
When an initiating signal is received by the switch assembly 72 , the circuit board 74 operates to provide an initiating current through the signal line 84 and further allow continuity between the ground lead 86 and ground lead 78 , thereby closing a circuit through the detonator 88 for initiating the detonator 88 . As shown, an end of the detonator 88 is directed towards the detonating cord 66 within the downstream perforating gun 62 2 , so that as the pressure wave of detonation passes along the length of the detonating cord 66 , the attached shaped charges 64 will in turn initiate to create perforations in an adjacent formation (not shown). Further illustrated in the embodiment of FIG. 3 , a collar-like connector 90 is provided on the downstream end 91 of the cartridge sub 68 . In an example, the connector 90 is formed from a conductive material and is an annular member that circumscribes the downstream end 91 . Further in the example of FIG. 3 , the diameter of the cartridge sub 68 reduces at the downstream end 91 . When the cartridge sub 68 is connected to the downstream perforating gun 62 2 , connector 90 coaxially inserts within an annular electrical receptacle 92 shown provided in the downstream perforating gun 62 2 . The electrical receptacle 92 is electrically conductive, so that the combination of the electrical receptacle 92 and connector 90 provides an electrical coupling between the exit lead 80 and communication line 82 . The coupling thus provides a means for transferring a signal or signals between the cartridge sub 68 and the downstream perforating gun 62 2 , and along the length of the perforating system 60 . It should be pointed out that the orientation of the cartridge sub 68 and perforating guns 62 1 , 62 2 is reversible; so that when a string of multiple guns is formed, the signal that passes along the signal lines and through the switch assembly 72 may start at the lower end of a perforating gun string and travel upwards, or initiate at the upper end of the string and travel downwards within the wellbore.
FIG. 4 illustrates an example embodiment of a lower end of the perforating system 60 and with an alternate embodiment of a cartridge sub 68 A. In this example, an inlet lead 76 and ground lead 78 extend through the cartridge assembly 70 A to a switch assembly 72 . However, the exit or downstream side of the switch assembly 72 includes a single continuous signal line 84 A that terminates at a connector 90 A. The example of the connector 90 A illustrated in FIG. 4 is a hemispherical-shaped member with a collar-like base circumscribing a cylindrical tip of the cartridge assembly 70 A. Similar to the connector 90 of FIG. 3 , connector 90 A of FIG. 4 is formed from an electrically conducting material. Further, in the embodiment of FIG. 4 , the perforating system 60 is set within a wellbore 93 lined with casing 94 that is cemented within the formation 96 . In this embodiment, a bridge plug 98 is shown set within a bridge plug sub 100 to form a bridge plug setting tool mounted on the end of the cartridge sub 68 A having the connector 90 A. Optionally, some other pressure actuated device may be provided on the end of the cartridge sub 68 A. In the example of FIG. 4 , the connector 90 A contacts an igniter (not shown) in the bridge plug sub 100 thereby providing electrical continuity between the signal line 84 A and the igniter. Delivering an electrical signal or electricity can activate the igniter for setting the bridge plug 98 . Setting the bridge plug 98 can cause it to expand from within the bridge plug sub 100 and into contact with the inner circumference of the casing 94 , thereby pressure isolating that section of the wellbore from another.
In one example embodiment, the connection between the cartridge sub 68 and upstream perforating gun may be a terminal assembly made up of a rod and pin connector, where the pin connector is mounted on a free end of the rod. In this example, a bushing circumscribes a mid-portion of the rod. The pin connector is in electrical communication with connector in the sub 68 by connections that extend through the end wall of the sub 68 . Circumscribing the portion of the terminal assembly adjacent the end wall is a spring connector that is in electrical communication with another connector in the sub 68 by connections extending through the end wall. Provided at a downstream end of the cartridge sub 68 opposite the terminal assembly is a downstream connector in which the exit lead 80 is connected at an end opposite its connection to the switch assembly 72 . Coaxially projecting from the end of the cartridge sub 68 and adjacent the detonator 88 is a spring connector; the spring connector communicates with the downstream connector by connection through the end wall at the downstream end of the sub 68 .
The spring connectors can provide connectivity on the upstream and downstream sides of the cartridge sub 68 . More specifically when the cartridge sub 68 is inserted within an example embodiment of a perforating string 60 , a connector sub couples to the upstream end of the cartridge sub 68 and receives the terminal assembly, within an axial bore formed through the connector sub. A receptacle is formed within the connector sub at a location set back from the entrance to the bore. The receptacle provides terminals for communication between a signal wire within the connector sub and the pin connector. As such, a signal traveling through the signal wire is transmitted through the terminals to the pin connector for delivery to the switch assembly. Also the insertion of the downstream side of the cartridge sub 68 into an end of the downstream perforating gun 62 2 . A connection assembly may be set within a bore formed in the end of the downstream perforating gun 62 2 . The connection assembly can be made up of a disc-like flange member set into close contact with the spring connector. A cylindrically-shaped base may depend coaxially from a side of the flange opposite the spring connector and set within a reduced diameter portion of the bore. Setting the base and bore diameters at about the same value anchors the connector assembly within the perforating gun 62 2 . A communication line, similar to the line 82 of FIG. 3 , may attach to the flange thereby providing communication from the exit lead 80 , through the assembly of connectors and spring connector, flange, and into and through the perforating gun 62 2 .
One example of a substantially complete perforating system 60 in accordance with the present disclosure is shown in a partial sectional view in FIG. 5 . In this example, a string 115 of perforating guns 62 1-n is disposed within wellbore 93 for perforating through the casing 94 and into the surrounding formation 96 . Further in this example, the cartridge sub 68 and the string are oriented so that signals received in the switch assembly 72 are from a location farther downhole; thus signals traveling in the string in a direction towards the surface. Depending on the instructions programmed into the switch assemblies 72 , the direction of perforating may also travel upwards within the bore hole 92 rather than from the top to the bottom.
In one example, the string 115 is assembled by providing cartridge subs 68 with a cartridge 70 within. Each of the cartridge subs 68 can then be coupled with a perforating gun 62 so connectors 90 in their respective downstream ends 91 mate into electrical receptacles 92 as illustrated in FIG. 3 . Connector subs 116 may optionally be provided for coupling upstream ends of the cartridge subs 68 with an upstream perforating gun. As described above, engaging the cartridge sub 68 with the downstream perforating gun provides a generally seamless way of forming an electrical connection between adjacent bodies in a perforating string. Moreover, the electrical connection occurs substantially simultaneously with coupling of the cartridge sub 68 and perforating gun 62 , so that manually forming electrical connections is unnecessary. Thus by connecting a repeating series of perforating guns 62 and cartridge subs 68 , the string 115 can be formed so that electrical communication extends substantially the length of the string 115 via contact between successive connectors 90 and receptacles 92 .
Further illustrated in the example embodiment of FIG. 5 is a wire line 132 shown suspending the string of perforating guns 62 that is controlled from a surface truck 134 . An optional pulley system 136 aligns the wire line 132 above the wellbore 93 . An attachment sub 138 is provided on an upper end of the string for attachment and electrical connection between the perforating gun 62 and wire line 132 . A power source 140 and controller 142 are schematically depicted in communication with the surface truck 134 . The power source 140 and controller 142 also may selectively connect with the wireline 132 . While shown adjacent the surface truck 134 , the power source 140 and controller 142 may instead be housed in the surface truck 134 . In one optional embodiment, the controller 142 can generate and/or send control signals to the perforating gun string 115 via the wireline 132 . Thus examples exist wherein each cartridge sub 68 in the string 115 , and all components in each cartridge sub 68 , are in signal communication with the controller 142 by virtue of the connectivity between the connectors 90 and receptacles 92 . Similarly, electricity from the power source 140 can be delivered throughout the perforating string 115 and components therein for initiating detonation of the detonators 88 and bridge plug 98 .
The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. For example, the signals may include instructions for selective operation of the switch assemblies, may include electricity, or may be in the form of a pressure wave within a detonation cord. Optionally, instructions may be provided in the switch assemblies, either by storing the instructions in hardware, such as the circuit boards, or by signals traveling in the perforating string. Moreover, the connection embodiments described above may be used for connecting to any ballistic device in a downhole string. Examples include release tools, multiple backoff shots, firing heads, redundant firing heads, severing tools, setting tools, combinations thereof, and the like. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims. | A cartridge assembly for use with a perforating system having a contact terminal that connects to a perforating signal line when inserted into a receptacle end of a perforating gun. A detonator may be included in an end of the cartridge assembly for initiating a detonating cord in the perforating gun. The cartridge assembly is a modular unit that replaces the manual connections made when assembling a string of perforating guns. The cartridge assembly may optionally include a controller switch for controlling current flow through the cartridge assembly. | 4 |
CROSS-REFERENCE TO A RELATED APPLICATION
Reference is made to commonly assigned copending application Ser. No. 07/895,756, entitled SHUTTER RELEASE, and filed Jun. 9, 1992 in the name of Debby Hyun-Jin Kwak.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to the field of photography, and in particular to a camera assembly.
2. Description of the Prior Art
The vast majority of photographic cameras are intended for right-hand use, in that the shutter release is located proximate right-hand end portion of the camera body. This can make camera operation somewhat uncomfortable for a left-handed user.
SUMMARY OF THE INVENTION
A camera body has a pair of right-hand and left-hand symmetric openings for alternatively receiving a manually actuated camera device, such as a shutter release, thereby allowing the camera body to be tailored selectively for right-hand or left-hand use of the manually actuated camera device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front top perspective view of a photographic camera, according to a preferred embodiment of the invention;.
FIGS. 2A and 2B are front top perspective views of only parts of the camera body, showing a pair of right-hand and left-hand symmetric openings respectively, one of which is capped and the other of which has a bi-directional shutter release supported in it;
FIG. 3 is a detailed perspective view of the shutter release depicted in FIG. 2A;
FIG. 4 is a schematic view of electrical circuitry to be used with the shutter release depicted in FIG. 2A;
FIG. 5 is a front top perspective view of only part of the camera body, showing a shutter release which is an alternate version of the one depicted in FIG. 2A; and
FIG. 6 is a detailed perspective view of the shutter release depicted in FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention is disclosed as being embodied in a compact 35 mm camera. Because such photographic cameras have become well known, this description is directed in particular to camera elements forming part of or cooperating directly with the preferred embodiment. It is to be understood, however, that camera elements not specifically shown or described may take various forms known to persons of ordinary skill in the art.
Referring now to the drawings, FIG. 1 shows a photographic camera 1 comprising a camera body 3, a known taking lens 5, and a known viewfinder 7. As can be seen in FIGS. 2A and 2B, the camera body 3 has a pair of right-hand and left-hand symmetric openings 9 and 11 for alternatively receiving a manually actuatable shutter release in the form of a finger button 13. Preferably, the finger button 13 has two integrally formed coaxial pivot pins 15 and 17 centrally located with respect to opposite ends of the button. See FIG. 3. A pair of grooves 19 and 21 are formed in respective ribs 23 and 25 fixed within the camera body 3, proximate each of the right- and left-hand openings 9 and 11. The pivot pins 15 and 17 are snap-fitted into the grooves 19 and 21 at either one of the right- and left-hand openings 9 and 11 to support the finger button 13 for pivotal movement bi-directionally, i.e. in opposite directions as indicated by the double-headed arrow 27 in FIG. 3. A pair of symmetric surfaces 29 and 31 are formed on the finger button 13, to be manually gripped to pivot the button from an illustrated intermediate or non-operative position selectively to alternative terminal or operative positions against respective stops 33 and 35. The stops 33 and 35 protrude from identical switch bases 37 and 39 secured to the camera body 3 inwardly of the right- and left-hand openings 9 and 11. See FIGS. 2 and 4. A return spring, not shown, may be provided to bias the finger button 13 to its intermediate position from either one of its terminal positions.
Each of the switch bases 37 and 39 supports a single metallic-ribbon contact 41 and a pair of spaced metallic-ribbon contacts 43 and 45. An arm 47 projecting from the finger button 13 includes a metallic brush 49 that is continuously in engagement with the single contact 41 and a metallic brush 51 that is moved into engagement with the contact 43 or 45 in accordance with whichever one of the terminal positions the button is pivoted to from its intermediate position. The two brushes 49 and 51 are integrally formed. The contacts 41, 43 and 45 are connected to a known electromagnetic release 53 for a known camera shutter 55. When the finger button 13 is pivoted to either one of its terminal positions, the contacts 41 and 43 or the contacts 41 and 45 are electrically connected via the brushes 49 and 51 to cause the electromagnetic release 53 to be activated to, in turn, momentarily open the camera shutter 55 to make an exposure.
A cap 57 has two prongs 59 and 61 that secure the cap to the camera body 3, over whichever one of the right- and left-hand openings 9 and 11 that does not include the finger button 13. See FIGS. 1 and 2B.
FIGS. 5 and 6 show a variation 13' of the finger button 13. In lieu of the coaxial pivot pins 15 and 17, the variation 13' has a coaxial hole 63 for receiving two aligned pins 65, only one shows, that project from respective ribs 67 and 69 similar to the ribs 23 and 25.
The invention has been described with reference to a preferred embodiment. However, it will be appreciated that various modifications can be effected within the ordinary skill in the art without departing from the scope of the invention. | A camera body has a pair of right-hand and left-hand symmetric openings for alternatively receiving a manually actuated camera device, such as a shutter release, thereby allowing the camera body to be tailored selectively for right-hand or left-hand use of the manually actuated camera device. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present invention claims the benefit of U.S. provisional patent application 61/057,004 filed May 29, 2008, the entire contents and disclosure of which are incorporated herein by reference as if fully set forth herein.
[0002] This application is related to the following commonly-owned, co-pending United States Patent Application filed on even date herewith, the entire contents and disclosure of which is expressly incorporated by reference herein as if fully set forth herein. U.S. patent application Ser. No. (APP 1846), for “METHOD AND SYSTEM FOR MULTI-TOUCH-BASED BROWSING OF MEDIA SUMMARIZATIONS ON A HANDHELD DEVICE”.
FIELD OF THE INVENTION
[0003] The present invention relates generally to visual representation of multidimensional data.
BACKGROUND OF THE INVENTION
[0004] In a very short time period, YouTube has become one of the biggest video databases in the world. Featuring millions of videos, each one about 9 Mbytes big and several minutes long, thousands of new videos are uploaded each day. While YouTube user-generated videos are often short—minutes, not hours—iTunes, MSN, and Google Video offer short, episodic, and full length content. Other types of media with temporal dimension are also prevalent: for example, slide-shows, music, annotated music, sequenced images, and so on. All these media are more and more accessed via the mobile Web browser or via mobile applications installed on the mobile device. Most mobile Web sites and applications, however, offer very poor and limited tools for content-understanding, that is, tools to help customers quickly understand the gist or substance of the content, especially video, they are interested in.
[0005] “Content understanding” means the act of browsing through content in order to create a mental model of it to some sufficient degree. The user's sufficiency requirements may hinge on their ability to determine specific details such as: “Is a goal scored in the first 10 minutes of this football video?”, “Does the video have a scene in which two men fight onboard a helicopter?”, “Does the video have a scene in which a cat falls off a ledge after a baby scares it?”. The above types of questions are almost impossible to be resolved on today's Web-centric media sharing sites such as Yahoo!®, Google™ and YouTube. Thus the benefits of content-based browsing—especially with respect to video—are clear in cases where media content complexity is anything more complicated than “trivial”.
[0006] There are few effective tools for video content non-linear browsing and understanding on mobile devices. For example, FIG. 1 depicts YouTube on a mobile handset. YouTube.com does not provide informative “preview” information for videos apart from a few video keyframes. Content-understanding comes only from the keyframe, the video duration (e.g. 03:52 min), and the aggregated “user tags” created by the community. Complex content cannot be inferred (e.g., “is this the one where the guy on the sled hits the other guy after going over a ramp?”).
[0007] YouTube's Warp tool shows the relationships between videos in a graphical way, but not fine-grain details of the content within a given video. YouTube's Java application for smartphones only previews content from a single keyframe. MotionBox.com and other similar sites use the prevalent technique of showing a static keyframe strip below the movie. Guba.com employs a 4×4 matrix of keyframes for any given video, but the representation is non-navigable. Internet Archive Website lays out one keyframe for each minute of a video in question, to allow a somewhat weak or diluted view of the video content. Finally, note that the current art also enables a limited video understanding through “tags” but that the tag paradigm (also known as “folksonomy”) has several drawbacks including: weak semantics, low scalability, lack of hierarchy. These drawbacks make it unsuitable for deep video content understanding.
BRIEF SUMMARY OF THE INVENTION
[0008] The inventive system is a compact and highly effective way for users to quickly, systematically, and non-linearly browse media (especially video) content in order to make a “watch/no-watch”, “rent/no-rent”, and/or “download/no-download” decision. This inventive system can run upon the smartphone or any other mobile device. A data connection (cellular, Wi-Fi) can be used to access a media catalog (such as a video storefront for video selection). An associated media server may serve metadata and key segment (e.g., video keyframes) to the smartphone on demand, allowing the rendering of a compact, customized, pixel-efficient visual notation. As browsing operations are performed by a user upon this rendering, auditing and logging may occur, e.g, for billing or profiling purposes. In one embodiment, a mediation server could sit in-between the mobile user and the content provider, providing the content understanding information to the components running on the mobile device and auditing and billing. The summarization information could be deployed in a “hosted” mode in an application server.
[0009] The inventive system for generating and presenting summarization of mobile content having a plurality of media segments comprises an application on a mobile device having a screen, an assignment module assigning one or more of the media segments to one or more parts of the screen, a rendering module rendering the assigned media segments on the parts of the screen, a playback module playing back the assigned media segments in various qualities, a catalog module representing media metadata about the mobile content, a summarization module stewarding the media metadata, and a remote server storing the mobile content and the media metadata, wherein the application retrieves the mobile content from the remote server and accesses the assignment module, the rendering module, the playback module, the catalog module and the summarization module.
[0010] The main use cases enabled by the inventive application include the following. One use case lets mobile users choose media to browse from their mobile device, such that media are represented in a fashion that highlights their interesting regions to the users in a customized and effective way. Another use case lets mobile users browse temporal media in a highly pixel-efficient manner that also maintains and renders the notions of temporal “focus” and “range”, allowing a highly non-linear browse mechanism. Another use case lets mobile users browse media interactively on their cellphone in a lightweight way that does not compromise the original media. Yet another use case lets mobile users playback media in a way that does not compromise original media. Still another use case lets mobile users mark and see community hotspots within media.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention is further described in the detailed description that follows, by reference to the noted drawings by way of non-limiting illustrative embodiments of the invention, in which like reference numerals represent similar parts throughout the drawings. As should be understood, however, the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
[0012] FIG. 1 depicts YouTube on a mobile handset;
[0013] FIG. 2 shows components of the invention;
[0014] FIG. 3 shows main case uses of the invention;
[0015] FIG. 4 shows an exemplary key rendering approach;
[0016] FIG. 5 shows the login procedure in an exemplary embodiment;
[0017] FIG. 6 shows a media comparison use case;
[0018] FIG. 7 shows side by side media tiles in an exemplary embodiment;
[0019] FIG. 8 shows the initial view use case;
[0020] FIG. 9 shows the flow to generate an initial view;
[0021] FIG. 10 shows the Browse media use case;
[0022] FIG. 11 shows the Browse media and add Hotspot use case;
[0023] FIG. 12 shows the Playback media use case;
[0024] FIG. 13 illustrates some playback and browsing features;
[0025] FIG. 14 illustrates additional playback and browsing features;
[0026] FIG. 15 illustrates more playback and browsing features;
[0027] FIG. 16 shows another hotspot browsing use case;
[0028] FIG. 17 shows the quit use case;
[0029] FIG. 18 shows an e-commerce use case;
[0030] FIG. 19 depicts a typical YouTube video as represented in one embodiment of the invention system;
[0031] FIG. 20 depicts a tool that has been used to “zoom into” video content for further understanding;
[0032] FIG. 21 depicts a varying degree of peripheral information that can be displayed;
[0033] FIG. 22 depicts an Ecosystem 1 and related components; and
[0034] FIG. 23 depicts an Ecosystem 2 and related components.
DETAILED DESCRIPTION
[0035] The inventive system or tool runs on a smartphone, presents video content to the user, and allows interactive browsing for the purpose of content-understanding. The following assumptions are made: 1) a backend video repository provides media (e.g. keyframes, metadata, etc.) to the tool, 2) the smartphone has a reasonably sized screen that allows the rendering of graphics, 3) the content in question has a temporal dimension and a visual content dimension (e.g. video, surveillance, medical imagery, etc.), and is sufficiently complex or lengthy that simply fast-forwarding through it is not an effective way for a user to build a mental model of it.
[0036] FIG. 2 depicts the components of the system. The Application 10 is the main application that obtains input from both the user (interactions) and from the server and uses an appropriate module in response.
[0037] The Assignment component 12 assigns media segments to parts of the screen depending on the media type, an optional preferred assignment mode, and other parameters. Assignment 12 chooses the subset of individual media (e.g., video frames) that should be displayed on the interface. In one embodiment, Assignment 12 is based on choosing media units so that they are sampled in a temporal equal pattern from the user's current preferred range of view (e.g. n units every t time units), centered around the user's current preferred temporal focus. Other modes are possible such as focusing assignment on semantically “important” units such as, but not limited to, scene transitions, or camera cuts, or by focusing on segments of the media previously identified as more interesting to a given user or community.
[0038] The Rendering component 14 draws the overall imagery according to an assignment pattern gained from Assignment component 12 . Rendering 14 renders media segments onto the mobile device's screen. The Rendering mode 14 might be a function of the user, the media type, or some other local or global policy. Rendering component 14 maps an assignment of a layout to a rendering of the layout on the pixelspace of the screen. In one embodiment, a pixel-efficient “ring”-type rendering scheme would render the media segments identified in Assignment 12 onto the layout pattern contained in Rendering 14 , consisting of a central rectangular focal segment on the screen which is has several rings of smaller rectangles rendered around its perimeter until the outer edge of the screen is reached.
[0039] The Playback component 16 handles the playback of media and also the granularity or other obfuscation techniques depending on the attributes of this user, media, or session. Playback 16 preloads, caches and plays-back segments of the media back to the user. Playback 16 may be performed using the same media segments provided for the browsing views or may communicate with a networked server, enabling playing of a “full” version of the content streamed over the network, or downloaded in full. In the case where the video content owner does not want to compromise or risk theft or re-use of video, the Playback component 16 can be configured to emulate a playback by, for example, presenting the media segments in the current range of view in rapid fashion on the device. Alternatively, the Playback component 16 might use a full version of the media in question for playback but apply “blurring” or visually obscuring the content or might change the sampling rate of the content so as to markedly reduce quality and protect original high-quality content.
[0040] The Catalog component 18 is a representation of some of the media metadata available to a particular user, including the media currently being browsed. Catalog 18 includes metadata about the media available to this user, including community hotspots and user hotspots. This metadata can be loaded from a server or from a local cache on the device. The Catalog 18 is accessed by other components of the invention, and contains a series of entries of metadata describing media available to the user. The Catalog 18 can be downloaded in whole or in part from a remote server 20 and stored in memory on the device. For each media available to the user, the Catalog 18 lists important related information: the ID, the index for listing purposes, URL's to where the media and related data (such as reset view icons and other related icons) reside remotely, descriptors, community hotspots (e.g. each of which is comprised of a focus area and range), available rendering, quality and playback modes for this media, and an “interest index” corresponding to how interesting the server thinks the user will find this media. Accordingly, attributes and information stored by the Catalog 18 can include: media ID, local index, media server links, media resetview link, number of units, list of media descriptors, list of community hotspots, available visual render modes, available playback modes, available qualities, interest estimation for user. Catalog entries are generated with respect to the user requesting them, so that not every user sees the same metadata for a given media. Available rendering modes might include: single shot browsing, “ring” mode, standard thumbnail mode, etc. A rendering mode is interpreted by both the Assignment 12 and Rendering 14 components.
[0041] Remote Servers 20 include a Media Server role and a Control Server role. The Media Server role stores media, media metadata, and media segments for access by the inventive application. The Control Server role stores rules and Business logic and is used by the application in support of various use cases of the inventive application. The servers are networked to the wireless device running the application and can be implemented on a single server or distributed.
[0042] The Summarization profile component 22 stewards the metadata and global browsing constraints and characteristics of this user. Summarization profile 22 includes the constraints affecting the browsing experience of a given media for a given user. The Summarization profile 22 , like the Catalog 18 , is accessed by other components of the invention. The Summarization profile 22 , among other things, encodes the constraints and media browsing limitations that should be imposed on the user at a global level (e.g. that apply whenever the user is browsing). These might include issues related to: the allowable visual quality that is seen by the user, the level of advertisement that is inserted into sessions, the sort of playback modes allowed for this user, and others. Summarization profile 22 also encodes the user's IF), the user's browse history with a given media, the user's account balance and the user's hotspots within the given media. Information in the Summarization profile 22 can include: user account balance (credits, dollar amounts, etc.), user media history, user key/ID, user hotspots, user session browse trace, user visual render constraints, user quality constraints, user playback constraints.
[0043] In the case that there are several representation and browsing options available to users for a given media and there is only one option available in the user's Summarization profile 22 , then the latter will take precedence. This could be the case, for example, if there are low, medium, and high quality playback modes available for a media (and listed in the Catalog 18 ) but for business or accounting reasons the user is only allowed to use the low quality playback (which is the only option available in her profile).
[0044] High level use cases of the inventive tool are shown in FIG. 3 . Once initialized, the invention is largely triggered by end user interaction with it. Generally, in response to the user, the invention makes a reassignment 12 to the visual content on the mobile device screen and re-renders it 14 . Thus, assigning media and visual components to areas of the mobile screen according to an algorithm, and rendering those visual components as renderable graphics, are two key functions of the invention and are functionally provided by Rendering 14 and Assignment 12 components.
[0045] As depicted in FIG. 3 , the end user drives the invention algorithms and procedures by interacting with the visual part of the invention (the application) using some input mechanism which includes—but is not limited to—keypad, touchscreen, stylus, brain-computer interface. The main use cases are: logging in 24 , selection and comparison 26 , browse 28 , playback media segments 30 , manage hotspots 32 , “purchase” 34 including purchase, rent, e-commerce, etc., SmartView 36 and SmartPlay 38 .
[0046] Logging in 24 uses the application to sign in to the server (using an ID and password). The login serves as the gateway into further interactions. Current practices (such as cookies) may be used to maintain a session between the device and the logged-in actions incurred on the server.
[0047] Selection and comparison 26 enables presentation of an intuitive visual representation of various media in a side by side fashion on the smartphone or mobile screen. This allows the user to browse and compare media at a high level and choose which ones she'd like to “explore”.
[0048] During Browse 28 or in a browsing session of a media, the invention continually reacts to user input, reassigns media segments, talks to backend servers and local components, and re-renders information on the screen according to Assignment 12 .
[0049] Manage hotspots 32 includes the invention's capability to let the user store and manage spots of interest in the media and to see and browse hotspots created by a community of users.
[0050] Purchase 34 includes the ability of the invention to convey to an e-commerce system the details of what aspects of the media are being examined by the user, such as for purchase, as well as past browsing activity.
[0051] SmartView 36 provides the ability of the system to generate a small and dense visual representation of a given temporal media, e.g., Video. This view may be customized to the users interests. SmartView 36 also refers to the ability to display an initial browsing view that rests on the most key part of the media (relative to this particular user).
[0052] SmartPlay 38 provides the ability of the invention to accept parameter modifications during playback such that the user's media playback experience changes dynamically, e.g. becomes less pixilated, becomes lower quality. SmartPlay 38 can include Block, “Blur”, “Pixelate”, Insert (or remove) advertisements (ads), and Replace units.
[0053] FIG. 4 illustrates a main function of the Assignment 12 and Rendering 14 components. Initially, a mobile screen viewable area exists. One area for “focus” rendering is chosen. The remaining areas are partitioned into segments and ordered temporally. The selection and partitioning may be repeated or iterated. Finally, the focus area with the most number of pixels, resolution, detail and so on, or with the most relevant data to the user at any moment is rendered. Also, the remaining content in the view is rendered by laying it out in the understood rendering pattern. Accordingly, the segments in the rings can be temporally ordered from the top-left and sampled equally from the current range; the sampling, however, can use any algorithm. The center keyframe is called the “focus” and the view range is the portion of the video surrounding the focus frame that is currently under scrutiny. The range of content currently displayed can be understood by scanning the keyframes clockwise from the top-left, or in some other pre-arranged ordering. Thus the central area of the display is the “focus” area, or area of detail. The outer areas of the display are context, or peripheral information; although this area shows less detail, it reveals other aspects of the content, e.g., temporal relationships. There is a temporal relationship between all the components that can be implicitly inferred by the viewer.
[0054] In one particularly important assignment mode, the Assignment component 12 divides the mobile screen into a central region and periphery regions. In the central region, Assignment 12 always assigns something of high relevancy or interest at the given moment, for example, the current focus of the browsing session, e.g., one video frame. Around the central region, the Assignment component 12 divides up the remaining space into segments that have a temporal relationship to adjacent abutting segments. For example, it might order these segments such that from the top-left and reading clockwise the segments are temporally ordered, each one from a region later in time than the previous. The result is seen in the handheld screenshots shown in FIGS. 19-21 . Thus at any given moment, the visual view presented to the user corresponds to a particular subview of the media in question and shows not only a focus area but also contextual periphery information whose segments are sampled from regions both temporally before and after the temporal place of the focus. In addition, Assignment 12 may iteratively subdivide the regions of the mobile screen and perform these operations several times, e.g., on an iterative basis. The Rendering component 14 paints the imagery on the screen where it was assigned.
[0055] Once Assignment is determined, rendering functionality could occur on a server side. In such a variant, the server would generate the imagery according to Assignment 12 rules and user and device attributes transmitted to it, and respond with the imagery to the mobile application for display. In this way the number of network connections from application to server may be reduced, that is, instead of the application requesting each of the small visual components that comprise an individual browsing screen in a session, the application requests the whole screen or several “large” segments of it. Another advantage is in cases where computing and I/O are severely limited on the mobile device, a networked server may perform this Rendering 14 more efficiently than the device.
Key Use Cases and Invention Operation
[0056] FIG. 5 shows the login procedure in an exemplary embodiment. After supplying login ID and password, the application receives a key from the control server. The key is used in subsequent operations, has an expiration, and serves as an identifier of this user and this session. The application then asks the remote server for the catalog information for this user. The server responds with the details of the media catalog that have optionally been customized for this user. The application requests summarization information for this user. The server responds with the detailed summarization information it has stored. The application updates and/or passes this information to local components.
[0057] In one embodiment, catalog content may be a large dataset, and so may be transmitted in multiple requests, in partial form, e.g., only relevant entries, or in any other bandwidth-saving technique.
[0058] A media comparison use case is shown in FIG. 6 . A key aspect of the invention is the media selection opportunity. While media segments may be stored remotely or locally, the invention provides assistance to the user in selecting which media to browse. It does this by presenting a series of graphical media representations, side by side to the extent possible on the device screen to allow user comparison. Each of the individual representations stands for a single media, e.g., a tv show, movie, etc., and each is generated by the application or a component of the application on a server. Optionally, each is generated to focus on a given temporal region of the media that the application deems is important to the user. Thus the user is presented the “best” or “most attractive” view of the media based on her profile or other details that may include considering what the community finds interesting within the media. In one embodiment, the media tiles are shown side by side as in FIG. 7 .
[0059] The user chooses the media of interest. For example, FIG. 7 shows four media from which to choose. Each of these SmartView icons is optionally tailored to this user, to show what is most relevant to her. Relevancy level to a user can be increased in any number of ways that include—but are not limited to—focussing on the temporal center of the media, focussing on the part that has most community interest, focussing on the part whose content is likely to be of interest to the user, focussing on an area that received the most clicks from the user's past browsing sessions with the media, focussing on the part with—but not limited to—particular preferred colors, shapes, contrasts, and so on. The application 10 or remote Servers 22 can provide the analysis that shapes the SmartView 36 construction for a given user.
[0060] In one embodiment, the SmartView 36 algorithm described below can be used to create each of the icons in the visual catalog shown in FIG. 7 . A scroll option can be provided to enable scrolling through many multiple representations. Once the user has used this view to choose a media, it is loaded and a browsing session begins.
[0061] The initial view use case proceeds as shown in FIG. 8 . Once a media is selected by a user from the Catalog 18 for a browsing session, the application 10 reads the summarization aspects allowable for this media from Summarization Profile 20 , sets rendering options via the Rendering component 14 , and sets playback constraints via the Playback component 16 . Following this, an initial view of the media is presented to the user and the browsing session may begin.
[0062] FIG. 9 shows the flow to generate an initial view. Once a user has selected a media, the application generates a default initial view or a “SmartView” of the media. The SmartView is a particular assignment of media segments to parts of the application screen, in which the assignment selection has been tempered to reflect what might have a stronger impact on the user than a “default” view. A “SmartView” of a given media is a custom startup view that “feels right” for the given user. The view attempts to focus on the areas that will most interest the user, thus saving the user subsequent navigation time. SmartView 36 divides the media into n (optionally even) regions. For most temporal media, time is the dimension by which a media can be divided but the system is not limited to only this dimension. SmartView 36 then counts the number of community and user hotspots in each region, optionally giving user hotspots in this media different weight than others. The region with the most hotspot weight becomes the focus range, and the current focus becomes either the temporal center of the focus range or gravitates to a particular hotspot focus, e.g., the point with the most hotspots or a hotspot generated by a similar user. Alternatively, the SmartView could be generated, using the same algorithm or process, on the server side.
[0063] The Assignment component 12 of the application may encapsulate the algorithm for creating a SmartView for a given user and a given media, or this algorithm may optionally be stored on and loaded from a remote networked server. Once the assignment is done it is rendered and the user sees this initial view on the mobile device screen. This view can be returned to as necessary by the user during a browsing session through a menu option (e.g., “go back to ‘reset’ view”). An algorithm for generating the SmartView is:
[0064] SmartView Algorithm:
[0000]
Let m be the media
Let u be the user
Let T be the temporal duration of the media
Let t be the number of temporal regions to divide the media into
Let hw be a weighting factor for a user's hotspots
Let cw be a weighting factor for community hotspots
Divide m into t roughly temporal subsections (on average each has
temporal duration of
roughly T/t , but subsections may be chosen with any distribution)
For each segment i of m {
Uh = number of this users' hotspots focussed in this region
Ch = number of community hotspots focussed in this region
Seg_score[i] = Uh*hw + Ch+cw
}
Let TR be the region with the highest Seg_score
//now generate a smartview focus
If ( the smartview is hotspot agnostic)
Then Smartview_focus is the temporal center of segment TR
Else ( if smartview is hotspot aware )
Then Smartview_focus is the focus of one most important hotspot
from the set of all community and user hotspots focused in TR
//now generate smartview field of view
If ( random range enabled)
Then Smartview_range = random number bounded by the number
of temporal units in the segment TR and the number of temporal
units in the media m
Else if (whole range enabled)
Then Smartview_range = number of temporal units in media m
Else if (if smartview is hotspot aware)
Then the Smartview_range is equal to the range of the hotspot
chosen as the basis for the Smartview_focus
//Finally form the Smartview
Render a smartview with the attributes: focus = Smartview_focus,
and range = Smartview_range
[0065] The Browse media use case is shown in FIG. 10 . The user proceeds within a browsing session by interacting with the application. At any time, the user may either be choosing to change the view of the current media or interacting with menus to change or select options.
[0066] As FIG. 10 shows, when the user interacts to browse, the Assignment module 12 is asked by the main application to reassign the view based upon the input by the user. Browsing actions from the user can include “key presses”, “screen touches”, and so on, depending on the screen technology. Browsing actions can trigger re-assignment and re-rendering. If media segments required for the new view are remote or if a pre-caching mechanism is enabled, individual media segments may be retrieved from the media server in a single connection transmitting several segments or in several parallel or successive connections to the media server 22 . The Rendering component 14 is then asked to paint the screen and does so by using the media segments already in the cache (optional) or by requesting the media from the media server 22 . The summarization profile 20 logs the new view and the key presses that led to it, and the application may send this detailed log to a control server 22 for logging and per-click charging purposes.
[0067] The Browse media and add Hotspot use case is shown in FIG. 11 . At any point during a browse session the user may choose to add an interest “hot spot”. The context surrounding the hotspot is passed to the Summarization Profile 20 who stores it. Alternatively, the user may delete an existing hotspot in the media and the Summarization Profile 20 removes it permanently.
[0068] In general, a hotspot is a current “view” into the media and is meant to save what the user currently sees for later processing and sharing. What the user sees is generally focused on a given discrete region of the media and has a given discrete range of view. The range of view extends from two media units up to the number of media units available for rendering in the given media. For example, the user might be looking at media unit 52 with a range of 159 around that focus. When the user quits the application other hotspot related operations occur, such as optional syncing with a networked Server.
[0069] FIG. 12 shows the Playback media use case. During a browsing session, the user may desire a more dynamic “playback”-like experience that corresponds to the current focus and field of view of the tool. In the Playback media use case shown in FIG. 12 , the user makes an interaction corresponding to her desire to “playback”. The application sends a request to the Playback component 16 , indicating the context, e.g., focus, region, of the media. In all cases, if a media segment, e.g., video frame, is local, e.g., in a memory cache, then no request to the media server need be sent.
[0070] Optionally, the Playback module 16 may read summarization policies from the Summarization Profile 20 and the Playback module 16 will reconcile the quality of playback desired and allowable for this media and region of the media. In an exemplary embodiment, SmartPlay 38 options include ad insertion, pixelation and other deliberate quality degradation, obfuscation, and blocking.
[0071] If no SmartPlay 38 options are enabled and the media segments are not cached, then the Playback module 16 retrieves them from a Media Server 22 and the Rendering component 14 renders them. If an ‘insert ads’ SmartPlay 38 option is enabled then the Playback module 16 may optionally communicate with a Media Server 22 to retrieve an advertisement icon that should be overlaid on a segment. This can happen on a per segment basis or Playback may load and cache all the ads from the Media Server before playback. Alternatively, ads may be pre-cached locally or remotely. Ads may be chosen to match interests in a user's profile and stored in Summarization Profile 20 , or to match the semantics of the media segments being covered up or nearby the insertion point. For example, if a media unit relating to a house is covered by an ad, perhaps the ad is chosen from a Home Repair store. If a ‘quality adjust’ SmartPlay option is enabled, then, on a per-frame or per-segment basis, before passing the cached or loaded media for rendering, it will be blurred, pixelated, or otherwise reduced in quality to match the policies and constraints of the media and/or user, e.g., user might not be allowed to view a particular segment in high-quality. The Playback component 16 may choose to block the segments from view completely, e.g., by replacing them with a “not allowed” icon instead of blurring them.
[0072] Playback options may be modified during playback dynamically via a declaration of summarization changes from the media server. When these are received by the Playback module 16 they are updated by the Summarization Profile module 20 and the new policies take effect immediately. Such changes may be transmitted via the media server to the Application over the same channel as the media segments or over a different communications channel.
[0073] As an example, user X is browsing and playing back media M, but M is pixelated according to X's rights on this media. Meanwhile on some other device, X's partner Y acquires new rights on X's behalf and, once finalized, the Media Server 22 sends the new rights as in the below use case. The result is that X's playback becomes un-pixelated for the media, for this session and all subsequent sessions of media M.
[0074] FIGS. 13-15 illustrate playback and browsing features that include ad insertion 40 , parental control 42 , e.g., media segment blocking out, and playback pixelization 44 . FIG. 13 shows browsing and/or playback with Rendering component 14 inserting advertisement segments 40 at particular temporal locations. FIG. 14 shows browsing and/or playback with scene blocking 42 . Segments are completely blocked by a “not allowed” icon 42 . FIG. 15 shows pixelization of playback 44 to further obfuscate content and to preserve original content integrity.
[0075] A different hotspot browsing use case is shown in FIG. 16 . At any time the user may indicate she wishes to browse in the “locked hotspot based browsing” mode. Once selected as an option, the application disables all interactive features of browsing except for those that are used to switch between hotspots, that is, NEXT (including if at last, toggle to first), and PREVIOUS (including if at first, toggle to last), and those features needed to ‘cancel’ this mode of browsing. When the user chooses to traverse to either the next or the previous hotspot, the Summarization Profile module is asked for this user's hotspots in this media. The Catalog 18 may be queried for the set of community hotspots in this media. The Application then determines which hotspot to traverse to next and asks the Assignment 12 and Rendering 14 modules to perform as per the next hotspot context (e.g. its focus and range). Typically, hotspots are ordered on the time dimension and so given a hotspot, the ‘next’ and ‘previous’ can be easily computed. Other dimensions, however, could be used, such as ‘next most important’, or ‘next most colorful’.
[0076] One algorithm the Application 10 can use to determine a hotspot to jump to upon user interaction is:
Let U be set of this users hotspots in this media (each hotspot has a focus and field of view). Let C be the set of community hotspots in this media (each hotspot has a focus and field of view) Let t be the temporal place currently displayed in the current hotspot If (next hotspot action chosen)
Then find the hotspot from U or C whose focus is greater than the current focus and is closest to the current focus.
If (previous hotspot action chosen)
Then find the hotspot from U or C whose focus is less than the current focus and is closest to the current focus.
If no such hotspot has been selected, show a message to the user or toggle to another one in sequence. Change the view to the selected hotspot's focus and field of view.
[0086] The quit use case is shown in FIG. 17 . The user interacts with Application 10 to indicate she wants to end a browsing session. The Application 10 asks the Summarization Profile module 20 to update the server. In response, Summarization Profile uses a network connection to an API of the Control Server 22 and sends all updated hotspots the user has created in this session, and all user browsing traces, to the Control Server 22 . These browsing traces can include the names of media browsed, and the full browse trace from this session including the individual clicks identifying which segments were clicked on for zoom in, zoom out, pan operations, playback, time spent on each “view”, and other metrics relating to user's browse behavior.
[0087] An e-commerce use case is shown in FIG. 18 . A given user may use the Application 10 to indicate that she would like to either purchase the media being browsed—in whole or in part—or to purchase the rights to additional browsing capabilities such as improved resolution, improved overall quality, less pixelation of content, fewer advertisements, more advertisements meeting certain criteria, less or no blocked media segments, and so on.
[0088] The user triggers this directly through the application by selecting menu options. Alternatively, the system might allow a policy to be setup so that when particular thresholds are met then e-commerce applications are automatically triggered. One example would be “if the user browses the media for more than 5 minutes or views more than 100 views of the media then automatically purchase it for her and notify her”.
[0089] Control Server 22 receives the e-commerce request and optionally forwards it to a local or partnered e-commerce server. The Control server responds to the Application 10 with data that comprises any new capabilities or constraints. The Application makes local updates to components and the browsing session experiences the new capabilities immediately. Alternatively, the user might have to restart the session to experience the new capabilities.
[0090] Visually, the inventive tool might render media onto the screen in any number of ways, however those that convey the notions of media focus and range at any and every rendering pattern are preferred. FIGS. 19 and 20 depict an embodiment of the invention interacting with a typical YouTube video. As shown in FIGS. 19 and 20 , the Application 10 presents a central key area in the screen's center, surrounded by one or more outer “rings”. In this embodiment, the proportions of the components are similar to the video content, e.g., square or rectangular. However, in general the components could take any effective “shape”, such as circular, oval, etc., and either the Rendering component 14 or the Media server 22 may be capable of converting the media segment between formats and proportions.
[0091] FIG. 19 points out various features that result from Rendering in this embodiment. As shown in FIG. 19 , individual components are adapted from the actual content. Details of the current view, range, and playback speed appear on the lower portion of the screen of the mobile device, and further options are available from pull down menus accessible from the lower portion of the screen.
[0092] The entire tiled view is interactive. Keypad keys are one way in which to interact with the representation, and are mapped intuitively. However, any input mechanism in which a user indicates areas of interest on the visual rendered part of the browsing interface are valid (e.g. touch screen, keypad, stylus, etc.).
[0093] For example, when using a keypad, the keys are mapped as follows. Clicks upon individual keyframe tiles result in a refocusing of the representation on the new region of the video using the selected segments as the new focus. Special clicks are possible, such as keypad “5” (clicking on the focus frame) which corresponds to a zoom function, that is, reducing the current range of view by some factor, e.g., by a factor of two or in half. Another click increases the current range of view. Thus, browsing both temporally (forwards/backwards) and zooming up and down into detail (showing more or fewer frames per time period) are easy and quick. The Application 10 allows for the instantaneous playback of any region of the media including: a) just the range currently being examined, b) the whole media, c) play all segments at once.
[0094] Several features of the browsing tool are user-configurable, including the number of rings (an important visualization tradeoff). The ring options are: a) No rings around the focus which takes up the entire screen (this is the default “playback” configuration), b) One ring around the focus, c) Two rings around the focus (e.g. allows fine grain view of content and meta-content (e.g. scenes)), d) Three or more rings. Computationally, the tool's main concerns are: assignment of media fragments to screen regions, rendering of the interface accounting for screen size, and managing segment playback.
[0095] FIG. 20 depicts a smartphone in accordance with the Application 10 that has been used to “zoom into” video content for further understanding. Note that when the “View Range” becomes small, more granularity can be understood from the surrounding context, e.g., we can now see roughly the action that comprises a whole scene.
[0096] FIG. 21 depicts a varying degree of peripheral information that can be displayed in one embodiment. The mobile device or smartphone on the right shows no peripheral information; only the focus area is displayed. The smartphone in the center displays a moderate amount of peripheral information; the focus area is larger and in the center of the display. The left-most smartphone displays more peripheral information at the expense of slight decrease in local detail.
[0097] In the above embodiment shown in FIGS. 19-21 the content in question is video, but it could be audio, image, or any other data, with or without a temporal dimension.
[0098] FIGS. 22 and 23 depict two Ecosystems and their related components. FIG. 22 shows an Ecosystem in which Summarization is provided by store-front or repository site. The Ecosystem comprises a smartphone hosting the Application 10 , a data network, web video store-front with Media Server, WiFi access points, and radio access network. The operation of this Ecosystem includes the following. Using the data network, a user chooses a video from the web video store-front. The video and metadata is retrieved from the Media Server, and sent to the user's device. The Application 10 arranges the video and enables browsing of it. The user chooses to buy the video of interest and purchases same from the web video store-front. The Application conveys the appropriate metadata to the store to identify the video in question.
[0099] FIG. 23 shows another Ecosystem in which Summarization is provided by a third party. This Ecosystem comprises a Service Provider hosting the Media Server in addition to the items in the above Ecosystem. The operation of this Ecosystem is similar to that of the Ecosystem shown in FIG. 22 with slight modification. When the user chooses a video, if the web video store-front does not have this video, it is retrieved from a Summarization Provider site to which the user is directed. The Summarization Provider sends video segments, such as individual media segments and/or metadata, to the user's smartphone. As with FIG. 22 , the Application arranges the video and enables browsing, and the user can buy the video of interest from the web video store-front.
[0100] Various aspects of the present disclosure may be embodied as a program, software, or computer instructions embodied in a computer or machine usable or readable medium, which causes the computer or machine to perform the steps of the method when executed on the computer, processor, and/or machine. A program storage device readable by a machine, tangibly embodying a program of instructions executable by the machine to perform various functionalities and methods described in the present disclosure is also provided.
[0101] The system and method of the present disclosure may be implemented and run on a general-purpose computer or special-purpose computer system. The computer system may be any type of known or will be known systems and may typically include a processor, memory device, a storage device, input/output devices, internal buses, and/or a communications interface for communicating with other computer systems in conjunction with communication hardware and software, etc.
[0102] The terms “computer system” and “computer network” as may be used in the present application may include a variety of combinations of fixed and/or portable computer hardware, software, peripherals, and storage devices. The computer system may include a plurality of individual components that are networked or otherwise linked to perform collaboratively, or may include one or more stand-alone components. The hardware and software components of the computer system of the present application may include and may be included within fixed and portable devices such as desktop, laptop, and server. A module may be a component of a device, software, program, or system that implements some “functionality”, which can be embodied as software, hardware, firmware, electronic circuitry, or etc.
[0103] The embodiments described above are illustrative examples and it should not be construed that the present invention is limited to these particular embodiments. Thus, various changes and modifications may be effected by one skilled in the art without departing from the spirit or scope of the invention as defined in the appended claims. | This invention involves a system and method to construct a visual representation of multidimensional data that works especially well for video. The system comprises an application on a mobile device having a screen, an assignment module assigning the media segments to the screen, a rendering module rendering the assigned media segments on the screen, a playback module playing the assigned media segments, a catalog module representing media metadata about the mobile content, a summarization module stewarding the media metadata, and a remote server storing the mobile content and the media metadata. The application retrieves the mobile content from the remote server and accesses the assignment, the rendering, the playback, the catalog, and the summarization modules. The system also comprises a method to log and analyze the browsing interactions of one or more users, and present a view of the media that reflects what is interesting to the user. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation of U.S. application Ser. No. 13/642,882 filed Nov. 26, 2012, which is a U.S. national stage of application No. PCT/JP2011/059413 filed on Apr. 15, 2011, which claims priority from Japanese Patent Application No. 2010-102860, filed on Apr. 28, 2010, the disclosures of all of which are incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to a portable terminal device such as a mobile phone and the like, and especially relates to a radio access system and a portable terminal device that support a communication system in relation to a plurality of radio access technologies (RATs).
BACKGROUND ART
In a communication system defined as Long Term Evolution (LTE) or Evolved Universal Terrestrial Radio Access (E-UTRA) in Third Generation Partnership Project (3GPP) standardization, a function called “Idle mode Signaling Reduction (ISR)” is introduced in order to reduce a frequency of location registration processing that occurs in relationship with a network when a portable terminal device, being compatible with a communication system (such as Global System for Mobile communications (GSM), Universal Mobile Telecommunications System, and the like) in relation to a plurality of RATs, moves among different RATs. When ISR is active, the portable terminal device holds both a location registration information parameter related to GSM or UMTS and a location registration information parameter related to LTE, both the location registration information parameters being received from the network. Then, the portable terminal device becomes ready to move between a GSM/UMTS area and an LTE area, for both of which location registration processing has already been carried out, without location registration processing with the network.
General descriptions on ISR are defined in non-patent literatures NPL1 to NPL3 that are specifications of 3GPP.
CITATION LIST
Non-Patent Literature
NPL1: TS23. 401: General Packet Radio Service (GPRS) enhancements for Evolved Universal Terrestrial Radio Access Network (E-UTRAN) access (http://www.3 gpp.org/ftp/Specs/html-info/23401.htm)
NPL2: TS24. 301: Non-Access-Stratum (NAS) protocol for Evolved Packet System (EPS); Stage 3 (http://www.3 gpp.org/ftp/Specs/html-info/24301.htm)
NPL3: TS24. 008: Mobile radio interface Layer 3 specification; Core network protocols; Stage 3 (http://www.3 gpp.org/ftp/Specs/html-info/24008.htm)
SUMMARY OF INVENTION
Technical Problem
Incidentally, if once an instruction on ISR activation is provide in an ISR function of 3GPP from a network after expiration of a location registration cycle timer owned by a portable terminal device, thereafter sometimes the portable terminal device does not start an ISR inactivation timer so that ISR remains activated. In this case, there arises a situation of conflict; namely the network operates on the premise of ISR being inactivated, meanwhile the portable terminal device operates on the premise of ISR being activated.
That is because each of the portable terminal device and the network has a location registration timer individually for synchronizing the status of location registration, and both the timers are not completely identical with each other, and specifically the timer that the network has is set to be longer in accordance with specifications.
Moreover, under conditions where arises the situation of conflict with respect to ISR between the network and the portable terminal device, if the portable terminal device moves into an area with a different RAT and then location registration processing is carried out, the network becomes unable to take over the location registration information of the portable terminal device between the areas of the different RATs.
That is because, in the case where the portable terminal device moves between areas in such a way as to cross over RATs, a terminal-specific identifier to be specified for a location registration requesting message, which the portable terminal device sends to the network, becomes different, depending on whether ISR is active or inactive (wherein, the identifier being one of Globally Unique Temporary Identifier (GUTI), Packet Temporary Mobile Subscriber Identity (P-TMSI), and the like). If the portable terminal device sends a location registration requesting message on the basis of ISR being active under conditions where arises the situation of conflict with respect to ISR between the network and the portable terminal device, the location registration information from the RAT before moving between the areas cannot be taken over inside the network in accordance with specifications in 3 GPP.
Moreover, in the case where, even after the portable terminal device moves into an area with a different RAT and then location registration processing is carried out, the network still cannot take over the location registration information of the portable terminal device between the areas of the different RATs, the portable terminal device is likely to receive an unnecessary request on releasing registration from the network.
That is because, in the case where the network cannot take over the location registration information of the portable terminal device between the areas of the different RATs, the network is allowed to request the portable terminal device to once release the registration and carry out again location registration processing, as the network's operation, in order to obtain correct location registration information of the portable terminal device.
Thus, it is an object of the present invention to give solutions for the subjects described above, and to provide a radio access system and a portable terminal device that can prevent in advance the situation of conflict with respect to ISR with the network.
Solution to Problem
According to a first aspect of the present invention, provided is a radio access system, including: carrying out location registration processing by a portable terminal device with a plurality of radio access technologies, at every time after a certain time period passes by way of activating ISR (Idle mode Signaling Reduction) between the portable terminal device and a network, which are able to communicate with each other through a communication system in relation to the plurality of radio access technologies; and enabling the portable terminal device to move without newly carrying out location registration processing between radio access technologies for which location registration has already been carried out; wherein, under conditions where the portable terminal device and the network hold the potential to have individually different status on whether the ISR is active or inactive, even if the network gives the portable terminal device a command to activate the ISR, the portable terminal device ignores the command.
It is preferable that, without carrying out location registration processing for a radio access technology having had location registration up to the time even after a passage of the certain time period, if the portable terminal device carries out location registration processing for another radio access technology under a situation where the ISR is inactive, the portable terminal device keeps the ISR being inactive, even though the network gives the portable terminal device a command to activate the ISR.
It is preferable that, in the case where the portable terminal device moves to the radio access technology having had location registration up to the time, after carrying out location registration processing for the other radio access technology, in order to carry out location registration processing, the portable terminal device requests the network to carry out location registration processing under conditions of a setup in which the network can take over location registration information between the other radio access technology and the radio access technology having had location registration up to the time.
Moreover, even in the case where the portable terminal device cannot carry out location registration processing for a radio access technology having had location registration up to the time, even after a passage of the certain time period under a situation where the ISR is active, if the ISR cannot be inactivated after a predetermined time period following the passage of the certain time period, even though the network gives the portable terminal device a command to activate the ISR, the portable terminal device may ignore the command.
According to a second aspect of the present invention, provided is a radio terminal device, including: a radio unit that can communicate via radio waves with a network by means of a communication system in relation to a plurality of radio access technologies; and a communication controller for controlling communication by the radio unit with respect to each of the plurality of radio access technologies; wherein, the communication controller carries out location registration processing with the network, with respect to each of the plurality of radio access technologies; the communication controller executes ISR in such a way as to enable moving without newly carrying out location registration processing between radio access technologies for which location registration has already been carried out; and under conditions where the communication controller and the network hold the potential to have individually different status on whether the ISR is active or inactive, even if the network gives a command to activate the ISR, the communication controller ignores the command.
Advantageous Effect of Invention
According to the present invention, it is possible as an effect to prevent in advance the situation of conflict with respect to ISR with the network.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a drawing that shows a configuration example of a portable terminal device to be used in a radio access system, together with an example of the use of the radio access system according to an exemplary embodiment of the present invention.
FIG. 2 is a diagram for explaining requirements of 3GPP specifications, and it is also a sequence diagram that shows an example of operations of the portable terminal device and the network.
FIG. 3 is a sequence diagram that shows an example of operations of the portable terminal device and the network shown in FIG. 1 .
FIG. 4 is a sequence diagram that shows an example of operations of the portable terminal device and the network, with respect to an operation of an ISR inactivation timer to be used by ISR.
DESCRIPTION OF EMBODIMENTS
An exemplary embodiment of the present invention is explained below in detail with reference to the accompanied drawings.
FIG. 1 is a drawing that shows a configuration example of a portable terminal device to be used in a radio access system, together with an example of the use of the radio access system according to an exemplary embodiment of the present invention. The drawing explains the contents as described below.
A portable terminal device 1 and a network 2 can communicate with each other by means of a communication system in relation to a plurality of RATs. In an example explained here, used as two RATs are E-UTRAN (LTE) and GERAN/UTRAN (GSM EDGE Radio Access Network/Universal Terrestrial Radio Access Network).
ISR is activated between the portable terminal device 1 and the network 2 , and then the portable terminal device 1 carries out location registration processing every time when a certain time period has passed in relation to the plurality of RATs. As a result, the portable terminal device 1 becomes movable between the RATs, for which location registration processing has already been carried out, without newly carrying out location registration processing. Incidentally, a system is configured in such a way that; under conditions where the portable terminal device 1 and the network 2 hold the potential to have individually different status on whether ISR is active or inactive, even if the network 2 gives the portable terminal device 1 a command to activate ISR, the portable terminal device 1 ignores the command.
The portable terminal device 1 includes: a radio unit 3 that can communicate via radio waves with the network 2 by means of a communication system in relation to a plurality of RATs; and a communication controller 4 for controlling communication by the radio unit 3 with respect to each of the plurality of RATs. The portable terminal device 1 further includes: a main controller 5 for controlling operations of the radio unit 3 and the communication controller 4 ; and a memory 6 for saving information instructed from the main controller 5 , and dealing with reading and writing operations.
The communication controller 4 includes: an LTE controller 7 for controlling a connection with E-UTRAN; and a 2G/3G controller 8 for controlling a connection with GERAN/UTRAN; wherein E-UTRAN and GERAN/UTRAN being inside the network 2 as a counterpart.
The LTE controller 7 includes an LTE transmit-receive controller 9 and an LTE transmit-receive processing section 10 . Being configured with communication control software, the LTE transmit-receive controller 9 controls messages and data to be transmitted to, and received from the network 2 as a counterpart. The LTE transmit-receive processing section 10 converts the messages and data to be transmitted to, and received from the network 2 as a counterpart, between one format with which the LTE transmit-receive controller 9 deals and the other format with which the radio unit 3 deals.
The 2G/3G controller 8 includes a 2G/3G transmit-receive controller 11 and a 2G/3G transmit-receive processing section 12 . Being configured with communication control software, the 2G/3G transmit-receive controller 11 controls messages and data to be transmitted to, and received from the network 2 as a counterpart. The 2G/3G transmit-receive processing section 12 converts the messages and data to be transmitted to, and received from the network 2 as a counterpart, between one format with which the 2G/3G transmit-receive processing section 12 deals and the other format with which the radio unit 3 deals.
In order to control the communication by the radio unit 3 , the communication controller 4 manages the following information:
Status of ISR (active/inactive) (to be managed with Temporary Identity used in Next update (TIN) as an internal parameter of the portable terminal device, in 3GP); Location registration information for the LTE network (TAU Periodic Timer, E-UTRAN deactivate ISR timer, Globally Unique Temporary Identifier (GUTI), and so on); and Location registration information for the GERAN/UTRAN network (RAU Periodic Timer, GERAN/UTRAN Deactivate ISR timer, Packet Temporary Mobile Subscriber Identity (P-TMSI), and so on).
FIG. 2 is a diagram for explaining requirements of 3GPP specifications, and it is also a sequence diagram that shows an example of operations of the portable terminal device 1 and the network 2 .
In this case, it is assumed that ISR is inactive in initial condition of the portable terminal device 1 (Step S 1 ). It is assumed that an LTE network 21 in the network 2 holds location registration information of the portable terminal device 1 at the time (Step S 2 ). This assumption means that, by that time, the portable terminal device 1 has successfully carried out location registration processing for the LTE network 21 . In the meantime, it is assumed that a GERAN/UTRAN network 22 in the network 2 does not hold location registration information of the portable terminal device 1 at the time (Step S 3 ). This assumption means that, at the time, location registration processing by the portable terminal device 1 is not yet carried out for the GERAN/UTRAN network 22 .
It is specified in 3GPP that, after a certain time period passes with the location registration being once carried out, the portable terminal device 1 tries to carry out again location registration processing for the network 2 . The passage of the certain time period is detected by means of expiration of a location registration cycle timer (Tracking Area Update (TAU) Periodic Timer, Routing Area Update (RAU) Periodic Timer, and so on) in the communication controller 4 . In the example shown in FIG. 2 , the expiration of TAU Periodic Timer is detected. When the location registration cycle timer (TAU Periodic Timer) expires (Step S 4 ), it is requested to start location registration processing, such as TAU. Unfortunately, under conditions that location registration processing cannot get started, for example, in the case of being positioned outside an LTE area, the location registration processing does not get started. In this case, it is specified in 3GPP that, the location registration processing does not get started, until a situation allows it to start next time.
Under the condition, the portable terminal device 1 moves into an area of the GERAN/UTRAN network 22 so as to be located inside a GERAN/UTRAN area (Step S 5 ). The portable terminal device 1 sends a location registration requesting message, such as RAU REQUEST, for starting location registration processing, such as Routing Area Update (RAU), to the GERAN/UTRAN network 22 (Step S 6 ). In response, the GERAN/UTRAN network 22 sends a message (such as RAU ACCEPT) expressing that the request from the portable terminal device 1 has been accepted. By making use of a parameter in the message, the network 2 gives the portable terminal device 1 a command to activate ISR (Step S 8 ).
In the example shown in FIG. 2 , although the location registration cycle timer on a side of the portable terminal device 1 expires at Step S 4 , location registration for the LTE network 21 is not yet carried out in the situation. Under the situation, as far as a location registration cycle timer (such as Mobile reachable timer) that a side of the LTE network 21 owns has not yet expired, the LTE network 21 assumes that location registration is still active. Accordingly, there is a chance that the GERAN/UTRAN network 22 assumes the location registration being in successful condition (Step S 7 ), and both the LTE network 21 and the GERAN/UTRAN network 22 are under a situation where the location registration is successful so that the network 2 recognizes ISR to be active. Nevertheless, as a matter of fact, after the location registration processing of Step S 6 , the location registration cycle timer of the LTE network 21 expires (Step S 10 ), the location registration information that the LTE network 21 owns about the portable terminal device 1 is released (Step S 11 ). At the time, although the side of the network 2 recognizes ISR to have been inactivated, the side of the portable terminal device 1 recognizes ISR to be active in accordance with the command from the GERAN/UTRAN network 22 (Step S 8 ) in the location registration processing at Step S 6 . As a result, there arises a situation of conflict with respect to ISR between the portable terminal device 1 and the network 2 .
Furthermore, under conditions where arises a situation of conflict with respect to ISR between the portable terminal device 1 and the network 2 , even if the portable terminal device 1 moves into a previous RAT (the LTE network 21 in the case of FIG. 2 ) and attempts to carry out location registration processing on the basis of ISR being active (Step S 12 ), the network 2 cuts off the processing (Step S 13 ). That is because a terminal-specific identifier specified for a location registration requesting message, to be sent by the portable terminal device 1 to the network 2 , has a conflict on whether ISR is active or inactive, and then the location registration information from the RAT before moving between the areas cannot be taken over inside the network 2 in accordance with specifications in 3 GPP.
FIG. 3 is a sequence diagram that shows an example of operations of the portable terminal device 1 and the network 2 shown in FIG. 1 . In this example of operations; without carrying out location registration processing for a RAT having had location registration up to the time (E-UTRAN (LTE) in this case) even after a passage of a certain time period, if the portable terminal device 1 carries out location registration processing for another RAT (GERAN/UTRAN) under a situation where ISR is inactive, the portable terminal device 1 keeps ISR being inactive, even though the network 2 gives the portable terminal device 1 a command to activate ISR.
In other words, after operation proceeds up to Step S 6 in the same manner as shown in FIG. 2 , even in the case where the network 2 gives a command to activate ISR in location registration processing at Step S 6 , the portable terminal device 1 does not activate ISR and just leaves ISR inactive (Step S 21 ).
Thus, when the portable terminal device 1 moves afterwards into an area of the LTE network 21 (Step S 9 ), and sends a location registration requesting message, such as TAU REQUEST, in order to carry out location registration processing for the LTE network 21 , a terminal-specific identifier to be specified at the time is for ISR being inactive (Step S 22 ). At the time, the portable terminal device 1 notifies the LTE network 21 that it is needed to take over the location registration information that the GERAN/UTRAN network 22 owns. Therefore, the LTE network 21 can take over the location registration information held at Step S 7 , from the GERAN/UTRAN network 22 (Step S 23 ). If once the location registration information is successfully taken over, ISR becomes active at the side of the network 2 so that a message transmitted from the LTE network 21 to the portable terminal device 1 also notifies of ISR being active (Step S 24 ). Receiving the message, the portable terminal device 1 activates ISR (Step S 25 ).
In the above description, explained for example is a case where a location registration cycle timer for the LTE network 21 expires, and the location registration information is taken over from the GERAN/UTRAN network 22 to the LTE network 21 . In an opposite manner, it is also possible that a location registration cycle timer for the GERAN/UTRAN network 22 expires, and the location registration information is taken over from the LTE network 21 to the GERAN/UTRAN network 22 .
Furthermore, even without setting ISR inactive actually in the portable terminal device 1 at Step S 21 , by way of specifying the terminal-specific identifier with ISR being inactive for the network 2 at Step S 22 , it also becomes possible to have the portable terminal device 1 practically ignore activation of ISR from the network 2 .
FIG. 4 is a sequence diagram that shows an example of operations of the portable terminal device 1 and the network 2 , with respect to an operation of an ISR inactivation timer to be used by ISR.
It is assumed that; under a situation where ISR is active, ISR is active in the portable terminal device 1 (Step S 31 ), the LTE network 21 owns location registration information of the portable terminal device 1 (Step S 32 ), and the GERAN/UTRAN network 22 also owns the location registration information of the portable terminal device 1 (Step S 33 ). Under the situation described above; in the case where no location registration processing can start because of, e.g., being positioned outside an LTE area, even though a location registration cycle timer of the portable terminal device 1 expires after a certain time period has passed (Step S 34 ) so that the location registration processing cannot get started, there starts an ISR inactivation timer (E-UTRAN deactivate ISR timer (T3423), and GERAN/UTRAN Deactivate ISR timer (T3323) are defined in 3GPP) (Step S 35 ). When the ISR inactivation timer expires after a certain time period has passed (Step S 37 ), the portable terminal device 1 puts ISR into status of inactivation (Step S 38 ). Furthermore, when a location registration cycle timer expires also at the LTE network 21 (Step S 39 ), the location registration information of the portable terminal device 1 is released (Step S 40 ). Even when ISR at the side of the network 2 gets into status of inactivation in this way, it is defined in accordance with specifications in 3 GPP that ISR is consistently in status of inactivation in both the portable terminal device 1 and the network 2 .
Nevertheless, if the portable terminal device 1 cannot execute a process of inactivating ISR, the portable terminal device 1 has ISR still in status of activation, and meanwhile the network 2 has ISR in status of inactivation. As a result, there arises a situation of conflict with respect to ISR.
Therefore, it is ensured that; even if a command for activating ISR is given to the network 2 , the portable terminal device 1 ignores the command under conditions where the ISR inactivation timer cannot get started. In this context, the “conditions where the ISR inactivation timer cannot get started” include, for example, a situation in which the location registration cycle timer (such as T3412) has already expired even though the network gives a command to activate ISR.
According to the embodiment of the present invention as explained above; even if the location registration cycle timer expires under conditions where ISR is not active, and afterwards the network 2 gives a command to activate ISR with respect to the location registration carried out in a different RAT, operation progresses in such a way that the portable terminal device 1 ignores the command so as not to activate ISR. Accordingly, even in the case where, with ISR not being in status of activation, the network 2 gives a command to activate ISR after the location registration cycle timer owned by the portable terminal device 1 expires, it becomes possible to prevent beforehand a situation of conflict with respect to status of ISR from arising between the portable terminal device 1 and the network 2 . As a result, it becomes possible, for example, to prevent unnecessary location registration from occurring, to reduce traffic with the network 2 , and to reduce battery power consumption of the portable terminal device 1 .
Moreover, as described above, in the case where the portable terminal device 1 moves between areas in such a way as to cross over RATs, the terminal-specific identifier to be specified for the location registration requesting message, which the portable terminal device 1 sends to the network 2 , is set with an appropriate value, depending on whether ISR is active or inactive. Therefore, crossing over areas of different RATs, the network 2 can take over location registration information of the portable terminal device 1 , by way of preventing beforehand a situation of conflict with respect to status of ISR from arising between the portable terminal device 1 and the network 2 , even when the portable terminal device 1 moves into an area of a different RAT, and carries out location registration there. Accordingly, there remains no chance to receive an unnecessary request on releasing registration from the network 2 . As a result, it becomes possible to protect a call connection supplied to a user from being interrupted by such an unnecessary request on releasing registration from the network 2 . | As a result of ISR being enabled between a portable terminal device and a network which are capable of communicating by using the communication protocols of a plurality of wireless access technologies, the portable terminal device performs position registration processing between the plurality of wireless access technologies and the portable terminal device each time a fixed period of time elapses, and the portable terminal device is able to move between the plurality of wireless access technologies that have already been registered, without conducting new position registration processing. At this time, if there is a possibility of there being a difference in ISR states (activated or not activated) between the portable terminal device and the network, the portable terminal device ignores any instructions issued by the network for ISR to be enabled in the portable terminal device. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a book binding device that binds papers ejected from a sheet processing unit such as a printer and a copy machine, and more particularly, to a milling unit of a book binding device, which removes a coating material adhered to cutting surfaces of coating sheets before a tape is adhered to the coating sheets so as not to generate any adhesion defect of the tape due to the coating material remaining on the cutting surfaces of the coating sheets during binding of the coating sheets.
[0003] 2. Discussion of the Related Art
[0004] Generally, a sheet processing unit 1 , as illustrated in FIG. 1 and FIG. 4 , includes a sheet carrying unit 2 , a sheet aligning unit 3 , a binding product conveying unit 4 , a receiving stacker 8 , and a binding device 5 . If sheets are carried in toward the sheet aligning unit 3 through the sheet carrying unit 2 , a predetermined number of sheets are stacked on a tray 16 and then are fed to the binding device 5 . Ends of a bunch of the sheets fed to the binding device are aligned based on a sheet aligning plate 21 and then are subjected to binding in a state that the sheets are fixed by a gripper 22 .
[0005] After the bunch of sheets 20 is moved to the binding device, a binding tape 33 is fed to a tape heating unit 25 , and heat is given to the tape fed to the tape heating unit so that an adhesive surface 33 a of the tap is adhered to the end of the bunch of sheets 20 , whereby a binding process of the bunch of sheets is performed.
[0006] The table heating unit 25 of the conventional book binding device, as illustrated in FIG. 3 and FIG. 5 , includes a square shaped heater 27 provided to rotate based on a support shaft 13 . The square shaped heater 27 includes planes A, B and C orthogonal to one another, wherein the plane B opposes the plane A, and the places C and B are selectively located on a front surface by rotation of the support shaft 13 .
[0007] Furthermore, it is configured that the distance D 1 between the plane B and the support shaft 13 is smaller than the distance D 1 between the plane C and the support shaft 13 .
[0008] In a state that the plane C of the heater 27 is located on the front surface, the tape 33 is fed to a place substantially parallel with the plane A of the heater through a tape feeding unit 15 . After the bunch of sheets 20 is moved to an adhesion place of the tape 33 in a state that the bunch of sheets 20 is gripped by a gripper (not shown), the end of the bunch of sheets 20 is tightly adhered to the plane A of the heater 27 together with the tape 33 .
[0009] If a part of the tape 33 is pressed by the plane A of the heater 27 and adhered to the end of the bunch of sheets 20 , the tape feeding unit 15 moves to its original place so as not to disturb the binding process.
[0010] The binding process will be described in more detail. As illustrated in step {circle around (1)} of FIG. 5 , the tape 33 is pressed onto the plane A of the heated heater 27 and welded to a top end of the bunch of sheets 20 .
[0011] Subsequently, after the tape feeding unit 15 is moved to its original place, the binding process of the bunch of sheets 20 is performed by the steps of {circle around (2)} descending the bunch of sheets 20 from the heater at a predetermined interval, {circle around (3)} rotating the heater 20 by 90° toward an arrow so that the plane B is located toward the front surface, {circle around (4)} welding the tape 33 to a side of the bunch of sheets 20 by ascending the bunch of sheets 20 , which has descended at a predetermined interval, toward the heater 27 , to weld the tape 33 to a side of the bunch of sheets 20 , {circle around (5)} upwardly moving the bunch of sheets 20 of which side is welded to the tape, and {circle around (6)} rotating the heater 27 to its original place to adhere the other end of the bunch of sheets 20 to the tape 33 by means of heat of the plane B.
[0012] However, if the coating sheets are subjected to binding using the aforementioned binding device, a part P where a coating material constituting upper and low coating layers 11 a and 11 b of the coating sheet 11 is pushed to a lower end layer of the coating sheets by a cutter blade is formed during a cutting process using a cutter. For this reason, a problem occurs in that adhesion between the cutting surface of the coating sheet and the tape is remarkably deteriorated.
SUMMARY OF THE INVENTION
[0013] The present invention is directed to a book binding device, which substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
[0014] An object of the present invention is to provide a milling unit of a book binding device, which removes a coating material adhered to cutting surfaces of coating sheets before a tape is adhered to the coating sheets, thereby increasing an adhesive surface between the coating sheets and the tape.
[0015] Another object of the present invention is to provide a book binding device that does not reduce adhesion of a tape and binding quality even in the case that a binding process is performed using coating sheets.
[0016] Other object of the present invention is to provide a milling unit of a book binding device, which can selectively mill a section of a tape adhesive part of a bunch of binding sheets in accordance with general sheets or coating sheets.
[0017] 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 scheme particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0018] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, a book binding device binding a bunch of sheets fed from a sheet aligning unit comprises a sheet aligning plate aligning a section of the bunch of sheets fed from the sheet aligning unit; a gripper fixing the bunch of sheets aligned by the sheet aligning plate; an adhesive unit feeding an adhesive member to the section of the bunch of sheets to bind the bunch of sheets; and a milling unit milling the section of the bunch of sheets before the bunch of sheets is subjected to binding by the adhesive unit.
[0019] The milling unit includes a drum type cutting tool cutting the section of the bunch of sheets, a cutting tool moving rod moving the cutting tool along the section of the bunch of sheets, and a driving motor rotating the cutting tool.
[0020] The cutting tool moving rod is provided with an earth powder tub at a lower part.
[0021] The earth powder tub is provided with an earth powder suction fan.
[0022] The adhesive unit includes a tape feeding unit feeding an adhesive tape to the section of the bunch of sheets, and a tape heating unit heating the tape fed by the tape feeding unit to adhere the tape to the section of the bunch of sheets.
[0023] The drum type cutting tool is provided with a plurality of cutting blades arranged radially.
[0024] The drum type cutting tool is provided to forward and retract in an orthogonal direction of the cutting tool moving rod, so as to adjust a milling thickness of the bunch of sheets.
[0025] According to the book binding device of the present invention, since the milling unit that can mill the section of the bunch of sheets is provide, an adhesion force equivalent to binding of general sheets can be maintained even in the case that coating sheets are subjected to binding, whereby binding quality is not deteriorated.
[0026] Also, since the section of the bunch of sheets is cut densely by rotation of the cutting tool when the section of the bunch of sheets is milled, an adhesive area between the adhesive and the bunch of sheets increases, whereby the adhesive force increases.
[0027] Finally, it is possible to obtain the book binding device of an improved function without complicating the device or modifying its structure.
[0028] 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 ATTACHED DRAWINGS
[0029] The invention will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:
[0030] FIG. 1 is a diagram illustrating a structure of a general sheet processing apparatus;
[0031] FIG. 2 is a sectional view illustrating a structure of a general binding device;
[0032] FIG. 3 is an elevational view illustrating a book binding device that includes a general tape feeding unit and a tape heating unit;
[0033] FIG. 4 is a diagram illustrating a binding state of a bunch of general sheets;
[0034] FIG. 5 is a diagram illustrating a binding process using a general book binding device;
[0035] FIG. 6 is a diagram illustrating a sectional structure of a general coating sheet;
[0036] FIG. 7 is a sectional view illustrating a book binding device according to the present invention;
[0037] FIG. 8 is an elevational view illustrating a coupling structure of a milling unit, a sheet aligning plate and a gripper of a book binding device according to the present invention;
[0038] FIG. 9 is a side view of FIG. 8 ;
[0039] FIG. 10 is an elevational view illustrating a milling unit of a book binding device according to one embodiment of the present invention;
[0040] FIG. 11 is an elevational view illustrating a state that a drum type cutting tool of a milling unit according to the present invention is moved along a cutting tool moving rod;
[0041] FIG. 12 a and FIG. 12 b are diagrams illustrating an operation procedure of a milling unit according to the present invention; and
[0042] FIG. 13 is an elevational view illustrating a milling unit of a book binding device according to another embodiment of the present invention.
[0000]
*Description of reference numerals of main parts in the
drawings
1
sheet processing unit
2
sheet carrying unit
3
sheet aligning unit
4
binding product conveying
unit
5, 105
binding device
8
receiving stacker
13
support shaft
15
tape feeding unit
16
tray
20
bunch of sheets
21
sheet aligning plate
22
gripper
22a
gripper ascending rotational
shaft
25
tape heating unit
27
heater
29
cutting blade
33
tape
33a
adhesive
40
milling unit
41
drum type cutting
tool
42
cutting tool moving rod
43
support rod
44
earth powder tub
45
pulley
46
driving motor
47
earth powder suction
fan
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0044] Hereinafter, technical configuration and operation of a book binding device according to the present invention will be described with reference to FIG. 7 to FIG. 13 .
[0045] FIG. 7 is a sectional view illustrating a book binding device according to the present invention;
[0046] FIG. 8 is an elevational view illustrating a coupling structure of a milling unit, a sheet aligning plate and a gripper of a book binding device according to the present invention;
[0047] FIG. 9 is a side view of FIG. 8 ;
[0048] FIG. 10 is an elevational view illustrating a milling unit of a book binding device according to one embodiment of the present invention;
[0049] FIG. 11 is an elevational view illustrating a state that a drum type cutting tool of a milling unit according to the present invention is moved along a cutting tool moving rod;
[0050] FIG. 12 a and FIG. 12 b are diagrams illustrating an operation procedure of a milling unit according to the present invention; and
[0051] FIG. 13 is an elevational view illustrating a milling unit of a book binding device according to another embodiment of the present invention.
[0052] In FIG. 8 and FIG. 9 , a tape feeding unit and a tape heating unit are not illustrated to avoid complexity of the drawings.
[0053] A book binding device 105 according to the present invention, as illustrated in FIG. 7 to FIG. 11 , includes a sheet aligning plate 21 , a gripper 22 , a tape feeding unit 15 , a tape heating unit 25 , and a milling unit 40 .
[0054] The sheet aligning plate 21 aligns the end of a bunch of sheets 20 fed to the binding device, and is fixed to a rotational shaft 21 a to rotatably move to a place where adhesion of a tape 33 is not disturbed when the tape 33 is adhered to the end of the bunch of sheets 20 . In other words, if the bunch of sheets 20 descends without being gripped by the gripper 22 after passing through the gripper 22 in a state that the sheet aligning plate 21 is rotated to allow its plane to be parallel with the end surface of the bunch of sheets, the sheet aligning plate 21 serves to align the end of the bunch of sheets. After the end of the bunch of sheets 20 is aligned in contact with the sheet aligning plate 21 , the gripper 22 fixes the aligned end of the bunch of sheets 20 by gripping it. Then, if a gripper ascending rotational shaft 22 a is driven to upwardly move the gripper 22 , which grips the bunch of sheets 20 , along an ascending guide 60 , the sheet aligning plate 21 rotatably moves to a place below the gripper 22 .
[0055] If the gripper 22 that fixes the bunch of sheets 20 as above ascends and the sheet aligning plate 21 rotates to expose the gripped end of the bunch of sheets 20 , the milling unit 40 is driven to mill the end surface of the bunch of sheets 20 .
[0056] The mill unit 40 includes a drum type cutting tool 41 , a cutting tool moving rod 42 constituting a moving path of the cutting tool, and a driving motor 46 driving the cutting tool. The cutting tool moving rod 42 includes a screw type rod, and rotates by means of a rotation force of a belt (not shown) secured to a pulley 45 to move the drum type cutting tool 41 in parallel with the cutting tool moving rod 42 in both directions.
[0057] A support rod 43 supported in parallel with the upper part of the cutting tool moving rod 42 serves to firmly support the drum type cutting tool 42 when the drum type cutting tool 42 moves in both directions, thereby guiding the drum type cutting tool 42 to slidably move.
[0058] The drum type cutting tool 41 is provided with a plurality of cutting blades 29 radially arranged. If the end of the bunch of sheets is exposed after the sheet aligning plate 21 is rotated in a state that the drum type cutting tool 41 is located at the end of a side of the bunch of sheets 20 , the drum type cutting tool 41 rotates with moving to the right side along the cutting tool moving rod 42 and the support rod 43 to uniformly and densely mill the gripped end of the bunch of sheets 20 at about 0.2-0.3 mm, thereby removing the coating material P adhered to the end of the bunch of sheets.
[0059] Rotation of the drum type cutting tool 41 is performed by the driving motor 46 .
[0060] Of course, if the bunch of sheets is not the bunch of coating sheets, the milling unit 40 of the present invention can be maintained in a standby mode without being driven.
[0061] Furthermore, the structure of the milling unit 40 according to the present invention as illustrated in FIG. 7 to FIG. 11 has been described that the drum type cutting tool 41 moves in both directions only and movement to the end of the bunch of sheets, i.e., milling thickness (width) of the end of the bunch of sheets is not adjusted optionally. However, the structure of the milling unit 40 is not limited to the structure illustrated in FIG. 7 to FIG. 11 , and its design may be modified in such a manner that a separate moving unit and rail are provided as illustrated in FIG. 13 so as to move the cutting tool 41 to move the end of the bunch of sheets.
[0062] In order that a worker optionally adjusts the milling thickness of the bunch of sheets, a technical mechanism that can forward and retract the drum type cutting tool 41 in an orthogonal direction of the cutting tool moving rod 42 is additionally required. For example, the technical mechanism can be configured in the structure of FIG. 13 .
[0063] An earth powder tub 44 can be provided at a lower region of the cutting tool moving rod 42 of the aforementioned milling unit. The earth powder tub 44 can be provided with an earth powder suction fan 47 that sucks the earth powder cut by the cutting tool to store the sucked earth powder therein.
[0064] After the aforementioned milling unit 40 is driven, the milling unit 40 moves to its original place, and the binding process of adhering the tape 33 to the end of the bundle of sheets is performed using the tape feeding unit 15 and the tape heating unit 25 .
[0065] The tape feeding unit 15 and the tape heating unit 25 constituting the adhesive unit are not limited to the structure illustrated in FIG. 3 and FIG. 5 . All types of units that can bind the bunch of sheets 20 using the adhesive can be used as the tape feeding unit 15 and the tape heating unit 25 , and can be applied to the book binding device of the present invention.
[0066] The operation of the aforementioned milling unit 40 according to the present invention will be described in detail with reference to FIG. 12 a and FIG. 12 b.
[0067] First of all, FIG. 12 a illustrates a state before the drum type cutting tool 41 of the milling unit according to the present invention is driven. The sheet aligning plate 21 is detached from the end of the bunch of sheets 20 and then located below the gripper 22 .
[0068] If the end of the bunch of sheets 20 is fixed by the gripper 22 and then exposed, the drum type cutting tool 41 of the milling unit starts to be driven.
[0069] When the gripper 22 that has fixed the bunch of sheets 20 moves to the height position of the drum type cutting tool 41 , it is preferable to obtain a sufficient rotation space so that the sheet aligning plate 21 is rotated without being gripped by the gripper 22 to expose the end of the bunch of sheets. However, if the sufficient rotation space is not obtained due to a wide width of the sheet aligning plate 21 , the gripper 22 may ascend sufficiently and then the sheet aligning plate 21 may rotate. Subsequently, if the end of the bunch of sheets fixed by gripper is exposed as the sheet aligning plate 21 rotates, the gripper 22 may descend to the height position of the drum type cutting tool 41 .
[0070] If the end of the bunch of sheets 20 gripped at the height of the drum type cutting tool 41 moves, the drum type cutting tool 41 rotates to mill the end of the bunch of sheets at 0.2!0.3 mm and moves to the right side as illustrated in FIG. 12 b.
[0071] After the end of the bunch of sheets is milled as above, the binding process of adhering the tape 33 to the end of the bunch of sheets is performed in the same manner as the related art.
[0072] The foregoing embodiments are merely exemplary and are not to be construed as limiting the present invention. The present teachings can be readily applied to other types of apparatuses. The description of the present invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. | A milling unit of a book binding device is disclosed, which removes a coating material adhered to cutting surfaces of coating sheets. A book binding device binding a bunch of sheets fed from a sheet aligning unit comprises a sheet aligning plate aligning a section of the bunch of sheets fed from the sheet aligning unit; a gripper fixing the bunch of sheets aligned by the sheet aligning plate; an adhesive unit feeding an adhesive member to the section of the bunch of sheets to bind the bunch of sheets; and a milling unit milling the section of the bunch of sheets before the bunch of sheets is subjected to binding by the adhesive unit. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention is directed to methods of reducing show through error in duplex printing.
[0003] 2. Description of Related Art
[0004] Duplex printing, i.e. printing in which an image is formed on both sides of a sheet of paper or other image receiving substrate, can be performed using a variety of known systems.
[0005] For example, duplex printing can be conducted with a system that forms images on both sides of a sheet at a single transfer station. In some duplex printing systems, after a sheet has received a first image on a first side by passing the sheet through an image transfer station, the sheet is inverted. A second image is then formed on a second side of the sheet by passing the inverted sheet through the same transfer station.
[0006] Positioning an image on one side of a sheet in a manner that coincides with the position of the image on the other side of the sheet can be difficult. Registration of a first image on a first side of a sheet with a second image on a second side of a sheet is not always accurate because of one or more registration errors that offset the first image relative to the second image. For example, a page number printed on the bottom-center position of the first side of a two-sided, printed document should align exactly with the page number printed on the reverse side. The offset of the page number on the second side of a sheet with respect to the page number on the first side of the sheet is a registration error that is extremely undesirable, and considered unacceptable in various printing industries.
[0007] Registering two images on the front and back sides of a single sheet of paper can be difficult but is essential in industries such as the offset printing industry. In this industry, duplex sheets are sometimes produced having a number of pages, of what will ultimately be a single, multi-page document, aligned on the front and back of a single sheet of paper. To create such a multi-page document, a sheet of paper is printed with multiple images on the front and back side of a single composite sheet. The single composite sheet is subsequently folded and segmented into individual pages. Each of the images on a first side a sheet must therefore be registered with a corresponding image on a second side of the sheet before the sheet may be segmented into individual pages.
[0008] Specifically, the first image that appears on the first side of the sheet and the second image that appears on the second side of the sheet are positioned so that identical images printed on both sides of the sheet are coincident with each other. In other words, two identical images printed on both sides of a sheet of paper form mirror images of each other since each image is printed with no apparent offset from the other. Thus, an image on the front side of a sheet would appear to be in perfect or transparent registration with the corresponding image on the back side of the sheet.
[0009] To ensure transparent registration, it is essential that the position of the printing substrate be precisely controlled. Active registration systems which sense document position and operate to correct the position of a copy sheet, if necessary, before an image is transferred to the copy sheet are well known. However, even if position is controlled, errors in magnification make achieving such transparent registration difficult. Errors can be attributed to the speed at which an image carrier, such as a photoconductive drum or photoreceptor belt or drum, operates. Magnification errors can also be attributed to the frequency at which a write clock or a pixel clock operates. Another source of magnification errors is the expansion or contraction of paper, coupled with variation in these properties from sheet to sheet. In order to correct such magnification errors, the speed of the photoreceptor belt or drum, or other such device, is adjusted, and the pixel clock frequency is adjusted.
[0010] The “show through” error that occurs when transparent registration is not achieved can be quantified by measuring of the displacement between two points, one on a first side of the sheet and one on a second side of the sheet, that are intended to be equidistant from a common sheet edge. This error is caused, at least in part, by the factors identified above. The portion of the error associated with paper shrinkage is often caused by fusing a printed image on the first side prior to printing of an image on the second side.
SUMMARY OF THE INVENTION
[0011] In various printing systems, which combine a wide range of paper types with very specific performance specifications, a method of reducing show through error is needed.
[0012] This invention provides systems and methods that make margin adjustments to reduce the effects of show-through in duplex printing.
[0013] This invention separately provides systems and methods that reduce show through error in duplex printing that compensate for different paper types and sizes.
[0014] This invention separately provides systems and methods that reduce show-through in duplex printing resulting from paper shrinkage or growth.
[0015] This invention separately provides systems and methods that reduce setup errors that occur when adjusting simplex and duplex magnification errors.
[0016] This invention separately provides systems and methods that compensate for errors that result from paper shrinkage caused by fusing during duplex printing.
[0017] In various exemplary embodiments of the systems and methods of this invention, show through is reduced by performing registration setup to adjust a pixel clock frequency and/or a photoreceptor belt or drum speed, determining an amount of residual magnification error after performing registration setup, determining margin shifts to reduce the amount of residual magnification error, and applying the margin shifts. In various exemplary embodiments of the systems and methods of this invention, paper shrink effects on registration can be compensated for using determinations made during a typical printer setup. Show through errors can be reduced without using a paper conditioner to pre-shrink or re-wet the paper.
[0018] In various exemplary embodiments of the systems and methods of this invention, the relationship between first side image and the second side image is evaluated to determine how the position of the paper and/or the size and arrangement of an image can be manipulated to compensate for the paper shrinkage effects caused by fusing.
[0019] In registration systems that use a common edge for simplex and duplex registration, the show through errors become progressively worse as the image moves away from the registration edge. Using information determined and stored in a non-volatile memory of a printing device during an image-on-paper registration setup, determinations can be made to apply a margin shift that results in a significant reduction in the maximum show through for each image.
[0020] These and other features and advantages of this invention are described in, or are apparent from, the following detailed description of various exemplary embodiments of the systems and methods according to this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Various exemplary embodiments of this invention will be described in detail, with reference to the following figures, wherein:
[0022] [0022]FIG. 1 is a top view of a sheet on which a registration test pattern has been printed;
[0023] [0023]FIG. 2 is a flowchart outlining one exemplary embodiment of a method for correcting show-through in duplex printing according to this invention;
[0024] [0024]FIG. 3 is a flowchart outlining one exemplary embodiment of a method for performing setup according to step S 2000 ;
[0025] [0025]FIG. 4 is a flowchart outlining one exemplary embodiment of a method for determining an amount of residual error according to step S 3000 ;
[0026] [0026]FIG. 5 is a flowchart outlining one exemplary embodiment of a method for determining margin shift according to step S 4000 ; and
[0027] [0027]FIG. 6 is a block diagram of one exemplary embodiment of a control system for reducing show through error in duplex printing, according to this invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0028] Before an image-on-paper registration setup operation is performed, it is likely that there are errors in the photoreceptor belt or drum speed and the pixel clock frequency. These errors would result in process and lateral magnification errors, respectively, as the image is exposed on the photoreceptor belt or drum. The process direction is the direction in which a sheet moves through a printing apparatus, or the direction parallel to movement from the leading edge to the trailing edge of the sheet. The lateral direction is perpendicular to the process direction. Process magnification error is magnification error in an image measured in the process direction, and lateral magnification error is magnification error in an image measured in the lateral direction.
[0029] After the image is transferred, the image is subsequently fused to a sheet of paper, and the paper, along with the images on the paper, shrinks, thereby compounding the magnification errors. There is no direct way to differentiate between the original photoreceptor belt or drum speed error, the pixel clock frequency error and the error caused by paper shrinkage. Also, because the first-formed image passes through the fuser one more time than does the second-formed image, there is also a difference between the magnification error in the image on the first side of the sheet and the magnification error in the image on the second side of the sheet.
[0030] In various printing devices, during an image-on-paper setup, the photoreceptor belt or drum speed and the pixel clock frequency are adjusted to correct for the average of the first side and second side magnification errors. Since this adjustment accounts for both machine errors and paper shrink errors, there are intentional residual errors, referred to herein as residual magnification errors, that remain for both the photoreceptor belt or drum speed and the pixel clock frequency. Residual errors are permitted to remain to ensure that the resultant images on a sheet, after accounting for the paper shrink during fusing, are the correct size. Due to residual errors, the first and second images formed on the photoreceptor belt or drum after the setup adjustments would, if measured, have a magnification error. This error has a linearly increasing effect on registration when moving from the leading edge of a sheet to the trailing edge of the sheet in the process direction and from the Start-of-Scan (SOS) sensor to the End-of-Scan (EOS) sensor in the lateral direction.
[0031] In some printing devices, registration occurs at the outboard edge and the leading edge of the sheet for the first side, and at the outboard edge and the trailing edge of the sheet for the second side. In such devices, the residual magnification errors can affect process registration on the second side. According to the methods of this invention, a margin shift is invoked to compensate for the setup errors due to the residual magnification error, as well as for the show through errors.
[0032] [0032]FIG. 1 illustrates a sheet 100 on which a registration test pattern has been printed. For the purpose of description only, the horizontal and vertical axes of the sheet 100 are referred to relative to the direction that the sheet moves through a printing apparatus. The process length (PL) is the length of an edge of the sheet 100 that runs parallel to the direction that the sheet 100 is fed through a printing apparatus. The lateral width (LW) of the sheet 100 is the length of an edge of the sheet 100 that runs perpendicular to the direction that the sheet 100 is fed through a printing apparatus.
[0033] The four edges of a sheet 100 can also be described relative to the direction that the sheet 100 moves through the printing apparatus. The outboard edge 135 and the inboard edge 140 are the edges that define the process length. The outboard edge 135 can refer to the edge of the sheet 100 that is closest to the registration surface of the printing apparatus, and the inboard edge 140 to the opposite edge, i.e., the edge that is farthest from a registration surface. The leading edge 125 and the trailing edge 130 are the edges that define the lateral width of the sheet 100 . The leading edge 125 is the forward edge as the sheet 100 moves through a printing apparatus, and the trailing edge 130 is the opposite edge.
[0034] Also, solely for the purpose of description, margin corrections towards different edges of the sheet 100 can be assigned positive or negative values. Adjustments towards the inboard and leading edges 140 and 125 of the sheet 100 can be assigned a negative value. Adjustments towards the outboard and trailing edges 135 and 130 can be assigned a positive value. The signs and names assigned to various aspects of the sheet 100 are not intended to limit the systems and methods according to the invention. The methods of this invention can be readily applied to any duplex printing apparatus for printing on any type of substrate, regardless of the names given to define various parts of the sheet 100 .
[0035] Various exemplary embodiments of the systems and methods according to this invention include performing a setup operation to adjust the pixel clock frequency and/or the photoreceptor belt or drum speed, determining an amount of residual magnification error after performing the setup operation, determining margin shifts to compensate for residual magnification and/or registration error, and applying the margin shifts.
[0036] As indicated above, during the setup operation, the photoreceptor belt or drum speed and/or the pixel clock frequency are adjusted as necessary to adjust for the average of the first side and second side magnification errors. After this adjustment, there are residual magnification errors that remain for both the photoreceptor belt or drum speed and the pixel clock frequency. In other words, the images on the photoreceptor belt or drum would, if measured, have a magnification error. At the completion of the setup operation, the registration is perfect at the outboard edge of the first side and the second side, at the leading edge of the first side, and at a distance x from the leading edge of the second side, depending on the size sheet used in the setup operation.
[0037] However, since setup specifications are often based on measurements from the trailing edge of the second side of any sized sheet, there is likely to be some second side process registration error on sheets that do not have the same process length as the test sheet used in the setup operation. This is because a sheet is often registered at the same physical edge for the first and second sides in the process direction. If the second side is registered to the trail edge of the sheet, and the registration is initially setup for a given process length, images formed on sheets of a different process length will be susceptible to the effects of magnification errors over the difference in length between the original process length and the new process length of the sheet being printed on. Various exemplary embodiments of the systems and methods according to this invention compensate for this error.
[0038] Assuming all other sources of error are equal to zero, which is what the setup operation attempts to accomplish, Table 1 shows the errors that remain because of the residual magnification errors and the paper shrink rates. As indicated above, PL refers to the process length of the sheet being printed on, while LW refers to the lateral width of the sheet being printed on. The residual process magnification error is referred to as c P . The first pass shrink rate of the sheet being printed on in the process direction is referred to as f 1P . The first pass shrink rate of the sheet being printed on in the lateral direction is referred to as f 1L . A distance from the leading edge of the second side where the registration error is zero is designated as x. The systems and methods according to this invention determine the errors as outlined below, and apply a margin shift to reduce the effects of show through that result from these errors.
TABLE 1 Process Lateral Side 1 Registration Error at Registration 0 0 Edge Side 2 Registration Error at Registration (PL − x) * c P 0 Edge Minimum Show Through Error at (PL − x) * c P 0 Registration Edge (absolute value) Maximum Show Through at Non- PL * (c P + f 1P ) − −LW * f 1L Registration Edge (absolute value) x * c P
[0039] In various exemplary embodiments of the systems and methods according to this invention, performing the registration setup operation includes, among other things, printing a registration test image on both a first side and a second side of a sheet, obtaining data by measuring the first image on the first side and the second image on the second side, analyzing the measurement data, and adjusting the pixel clock frequency error and/or the photoreceptor belt or drum speed error based on the analyzed data.
[0040] [0040]FIG. 2 is a flowchart outlining one exemplary embodiment of a method for reducing show-through in duplex printing according to this invention. As shown in FIG. 2, beginning in step S 1000 , operation continues to step S 2000 , where the setup operation is performed to adjust one or both of the pixel clock frequency and/or the photoreceptor belt or drum speed. Then, in step S 3000 , an amount of residual magnification error is determined. Operation then continues to step S 4000 . In step S 4000 , the margin shifts are determined that would compensate for the determined residual magnification and registration error.
[0041] Next, in step S 5000 , the margin shifts are applied. Then, in step S 6000 , operation ceases.
[0042] [0042]FIG. 3 is a flowchart outlining one exemplary embodiment of a method for performing the setup operation of step S 2000 . Accordingly, beginning in step S 2000 , operation continues to step S 2100 , where a registration test image is printed on each of the first and second sides of the sheet.
[0043] An exemplary embodiment of the sheet 100 on which a registration test pattern has been printed is illustrated in FIG. 1. In this embodiment, the registration test pattern comprises four cross-hairs 105 , 110 , 115 and 120 printed in the corners of the sheet 100 . According to the systems and methods of the invention, various measurements of the relationship between the position of the marks 105 , 110 , 115 and 120 of the test pattern, and the position of the test pattern on the sheet 100 are performed for both sides of a duplex printed sheet.
[0044] The registration test pattern can be any pattern that permits useful measurements of the first and second images and their positions on the sheet 100 to be made. Any suitable known or later developed pattern that permits measurement of parameters of an image that are usable in the systems and methods according to this invention can be used as the registration test image. However, the registration test image should, at least, permit the sizes of the first side image and the second side image in the lateral and process directions to be measured and thus compared. Using the registration test pattern arrangement illustrated in FIG. 1, various image parameters can be measured during the setup operation. These image parameters can include, but are not limited to, image squareness, image skew, lateral magnification, process magnification and image-to-paper position.
[0045] Next, in step S 2200 , data is obtained by measuring the first image on the first side and the second image on the second side. Obtaining the data can include any suitable known or later developed method of measuring the sizes of the first and second images and determining the positions of the first and second images on the sheet 100 . Measurements can be taken by any known or later developed, manual or automated method. Similarly, obtaining the data can include storing the data into any suitable storage or memory device, including, but not limited to, electronic memory. Obtaining the data can also include accessing data that has already been obtained, stored or recorded in prior processes.
[0046] Then, in step S 2300 , the obtained data is analyzed. Analyzing the data can include any known or later developed, manual or automated process of evaluating the obtained data. Analyzing the data can include employing the data in any routine or algorithm that will provide adjustments to overcome magnification error associated with pixel clock frequency error and photoreceptor belt or drum speed error. Operation then continues to step S 2400 .
[0047] In step S 2400 , the pixel clock frequency and/or the photoreceptor belt or drum speed are adjusted. Adjusting the pixel clock frequency and/or the photoreceptor belt or drum speed includes any suitable known or later developed method of adjusting the pixel clock frequency and/or the photoreceptor belt or drum speed, using the adjustments obtained in analyzing the data. Adjusting pixel clock frequency and/or photoreceptor belt or drum speed also includes any mechanical or electrical manipulations used to that are made to alter the pixel clock frequency and/or the photoreceptor belt or drum speed. This also includes any electronic or mechanical processes for implementing the adjustments. Then, in step S 2500 , operation returns to step S 3000 .
[0048] [0048]FIG. 4 is a flowchart outlining one exemplary embodiment of a method for determining the amount of residual error of step S 3000 . In step S 3000 , some of the measurements obtained during the setup operation, as illustrated above, are used to determine the relationship between the sizes of the first side and second side images, and thus the total effect of magnification error on the duplex printed document on the copy sheet. In various exemplary embodiments, the determination of residual magnification error is performed with regard to the process direction only, because the effect of the residual lateral magnification errors on the first side and the second side are often equal and opposite, and thus, cancel each other out.
[0049] As illustrated in FIG. 4, beginning with step S 3000 , operation proceeds to step S 3100 , where the process magnification error is determined. The process magnification error is a value that illustrates the difference between the nominal size of an image in the process direction and the actual size of that image when printed on a first side of a two-sided document. The first side process magnification error can be expressed as:
P ME1 =( d 1 −d nom )/ d nom (1)
[0050] where:
[0051] P ME1 is the process magnification error;
[0052] d 1 is the actual process image size of the first side image; and
[0053] d nom is the nominal process image size of the first side image.
[0054] Next, in step S 3200 , the first pass shrink rate is determined. The first pass shrink rate is a value that illustrates the effect of fusing after printing an image on a first side of a two-side document. The process first pass shrink rate can be determined by comparing the difference between the actual size of an image printed on a first side of a two-sided document and the actual size of an image printed on a second side of a two-sided document, in the process direction. The process first pass shrink rate can be expressed as:
f 1P =( d 1 /d 2 −1) (2)
[0055] where:
[0056] f 1P is the process first pass shrink rate;
[0057] d 1 is the actual process image size of the first side image; and
[0058] d 2 is the actual process image size of the second side image.
[0059] Likewise, the lateral first pass shrink rate can be determined by comparing the difference between the actual size of an image printed on a first side of a two-sided document and the actual size of an image printed on a second side of a two-sided document, in the lateral direction. The lateral first pass shrink rate can be expressed as:
f 1L =( c 1 /c 2 −1) (3)
[0060] where:
[0061] f 1L is the process first pass shrink rate;
[0062] c 1 is the actual lateral image size of the first side image; and
[0063] c 2 is the actual lateral image size of the second side image.
[0064] Then, in step S 3300 , a net shrink rate for a sheet of paper to be printed on is assigned or determined. To determine the amount of residual shrink error, the role of the sheet of paper itself must be included in the determination. For each sheet of paper, the net shrinkage of that sheet of paper in the process direction is some percentage, y, of the first pass shrink rate in the process direction P PS1 . While this percentage could be determined for each and every sheet that is printed, this is generally impracticable. Alternatively, a general rate for all sheets of paper could be used. In various exemplary embodiments of the systems and methods according to this invention, a value is assigned for each different type or size of paper that is used.
[0065] In various exemplary embodiments, the value y that is assigned to each paper is stored in the non-volatile memory of a printer.
[0066] The shrink error is defined as a negative value. Thus, in the process direction, a negative magnification error means the image is larger than the nominal image and a negative shrink error means the image is smaller than the nominal image. When determining the process shrink rate for the first side image, the net shrink rate of an individual sheet of paper, illustrated by the value y, is included. In various exemplary embodiments, separate values of y are assigned for different types and sizes of paper. In various other exemplary embodiments, a default value for y is assigned. In further exemplary embodiments, the value assigned for y is 0.30. The inventors of this invention have determined by testing a variety of papers that 0.30 is a usable default value for a variety of papers. The net first side process shrink error can be expressed as:
P SE1 =y*f 1P (4)
[0067] where:
[0068] P SE1 is the net process shrink rate for the first side image;
[0069] y is the net shrink rate of the sheet being printed on; and
[0070] f 1P is the process first pass shrink rate.
[0071] Next, in step S 3400 , the initial photoreceptor belt or drum speed error is determined. The measured magnification error on the first side is attributed to many factors. For the purposes of making a practicable determination of residual magnification error, four factors or sources of error are included in the determination. These sources of error include (1) the original photoreceptor belt or drum speed error, (2) the shrinkage that occurs during the first pass through the fuser, (3) the shrinkage that occurs during the second pass through the fuser, and (4) the re-acclimation of the sheet of paper. Thus, in addition to equation (1), the first side process magnification error can alternatively be expressed as:
P ME1 =(1+ m P )*(1+ f 1P )*(1+ f 2P )*(1+ g P )−1 (5)
[0072] where:
[0073] P ME1 is the first side process magnification error;
[0074] m P is the original photoreceptor belt or drum speed error;
[0075] f 1P is the first pass shrink rate;
[0076] f 2P is the second pass shrink rate; and
[0077] g P is the error attributed to re-acclimation.
[0078] Like the measured process magnification error on the first side, the first side process shrink error can be attributed to many factors or sources of error. The sources of error include (1) the shrinkage that occurs during the first pass through the fuser, (2) the shrinkage that occurs during the second pass through the fuser, and (3) the re-acclimation of the sheet of paper. Thus, in addition to equation (4), first side process shrink error can alternatively be expressed as:
P SE1 =(1 +f 1P )*(1 +f 2P )*(1 +g p )−1 (6)
[0079] where:
[0080] P SE1 is the first side process shrink error;
[0081] [0081] 1P f is the first pass shrink rate;
[0082] f 2P is the second pass shrink rate; and
[0083] [0083] P is the error attributed to re-acclimation.
[0084] In various exemplary embodiments of the systems and methods according to this invention, determining an amount of residual magnification error includes determining an original photoreceptor belt or drum speed error. Having described first side process shrink error and first side process magnification error in equations (1) and (4)-(6), the original photoreceptor belt or drum speed error extracted and expressed as:
m P =[( P ME1 +1)/( y*f 1P +1)]−1 (7)
[0085] where:
[0086] m P is the original photoreceptor belt or drum speed error;
[0087] P ME1 is the first side process magnification error;
[0088] y is the net shrink rate of the sheet being printed on; and
[0089] f 1P is the process first pass shrink rate.
[0090] Once the initial photoreceptor belt or drum speed error is determined in step S 3400 , it is then becomes possible in step S 3500 , to determine the amount of residual magnification error in the process direction. In step S 3500 , the initial photoreceptor belt or drum speed error can be compared with the actual adjustments made to the photoreceptor belt or drum speed in the course of the setup operation. The photoreceptor belt or drum speed adjustment rate is a ratio of (1) the difference between the adjusted photoreceptor belt or drum speed and the original photoreceptor belt or drum speed to (2) the original photoreceptor belt or drum speed. The residual magnification error can thus be expressed as:
c p =(1+ m p )*[1+( PR ADJ −PR OR )/ PR OR ]−1 (8)
[0091] where:
[0092] c p is the residual magnification error;
[0093] m P is the original photoreceptor belt or drum speed error;
[0094] PR ADJ is the adjusted photoreceptor belt or drum speed; and
[0095] PR OR is the original photoreceptor belt or drum speed.
[0096] After the residual magnification error is determined in step S 3500 , operation continues to step S 3600 , where operation returns to step S 4000 .
[0097] Determining the margin shift in view of the residual magnification error includes measuring a length and a width of the sheet of paper to be printed on, determining a total margin shift to reduce show through based on the amount of residual magnification error, and assigning portions of the total margin shift to the first and second sides. In various exemplary embodiments, the margin shift usable to adjust for the registration error must be determined and the margin shifts that compensate for residual magnification error must be determined. Further, margin shifts for lateral and/or process residual magnification errors must be determined for the first and second sides of the sheet. These various aspects of determining the margin shift can be conducted in sequence, simultaneously or any other combination or order.
[0098] [0098]FIG. 5 is a flowchart outlining one exemplary embodiment of a method for determining the margin shift according to step S 4000 . As illustrated in FIG. 5, beginning with step S 4000 , operation continues to step S 4100 , where the process length PL and lateral width LW of the sheet of paper to be printed on are determined. The process length PL and the lateral width LW can be determined by any suitable method.
[0099] Next, in step S 4200 , a margin shift to compensate for the registration error at the process registration edge of the second side is determined. As mentioned above, second side process registration may be affected by a difference in size between the sheet that was used during the setup operation and the sheet being printed on. A margin shift is implemented on the second side to account for this effect. This process margin shift for registration of the second side image can be expressed as:
S RP2 =−( PL−x )* c P (9)
[0100] where:
[0101] S RP2 is the process margin shift for the second side registration error;
[0102] PL is the process length of the sheet;
[0103] x is the distance from the current position of the second side process registration edge to the position where a second side process registration edge should be such that there would be no registration error, i.e. the difference in process lengths; and
[0104] c P is the residual process magnification error.
[0105] Next, in step S 4300 , a margin shift to compensate for show through effects at the leading and trailing edges of the sheet is determined. The process show through error, like the lateral show through, increases linearly as the distance from the lateral registration edge increases. Minimum show through refers to the amount of show through at the registration edge of the sheet, and maximum show through refers to the amount of show through at the opposite non-registration edge. The margin shift is determined to reduce the maximum show through on the sheet. According to various exemplary embodiments of the systems and methods of this invention, the expected minimum and maximum show through values are averaged for a given type and size of paper. This average show through is then partially compensated for by shifting the first side image and partially compensated for by shifting the second side image. The total process show through margin shift can be expressed as:
S PS =−PL*f 1P /2 (10)
[0106] where:
[0107] S PS is the total process margin shift for show through error;
[0108] PL is the process length of the sheet; and
[0109] f 1P is the first pass shrink rate.
[0110] Then, after determining the total amount of margin shift to be applied to correct show through in step S 4300 , in step S 4400 , the distribution of this margin shift between the amount that will be applied to shift the first side image and the amount that will be applied to shift the second side image is determined. The total margin shift can be distributed in any suitable manner. In various exemplary embodiments of the systems and methods according to this invention, the first side image is shifted toward the trailing edge of the sheet to compensate for show through error in the process direction. The process margin shift for the first side image can be expressed as:
S PS1 =−S PS *z (1)
[0111] where:
[0112] S PS1 is the first side process margin shift for show through error;
[0113] S PS is the total process margin shift for show through error; and
[0114] z is the proportion of the total process margin shift to be applied to the first side image.
[0115] In various exemplary embodiments of the systems and methods according to this invention, half of the margin shift is applied to the shift the first side image and half of the margin shift is applied to shift the second side image. In this case, z is equal to 0.5.
[0116] In various exemplary embodiments of the systems and methods according to this invention, the second side image is shifted toward the trailing edge of the sheet to compensate for show through error in the process direction. The process margin shift for the second side can be expressed as:
S PS2 =S RP2 −S PS *(1− z ) (12)
[0117] where:
[0118] S PS2 is the second side process margin shift for show through error;
[0119] S PS is the total process margin shift for show through error; and
[0120] z is the proportion of the total process margin shift to be applied to the first side image.
[0121] As with the determination of residual magnification error, the margin shift can vary for every sheet, as first pass shrink rate varies. However, in various exemplary embodiments, a determination of the process margin shift for every single sheet that is printed is not performed. Accordingly, as indicated above with regard to lateral margin shift, general or default assumptions about the general sheet of paper can be made.
[0122] Then in step S 4500 , determining the margin shift also includes determining a margin shift to compensate for show through effects at the inboard and outboard edges of a sheet. As discussed above, the lateral show through error at any point on the page increases linearly as the distance of that point from the lateral registration edge increases. Minimum show through refers to the amount of show through at the registration edge of the page. While maximum show through refers to the amount of show through at the opposite non-registration edge. The margin shift is determined to reduce the maximum show through on the page.
[0123] According to various exemplary embodiments of the methods, the expected minimum and maximum show through values are averaged for a given type and size of paper. This average show through is then partially compensated for by shifting the first side image and partially compensated for by shifting the second side image. Determining the lateral show through takes into consideration the lateral width of the sheet and the lateral first pass shrink rate of the paper. Lateral show through margin shift can thus be expressed as:
S LS =LW*f 1L /2 (13)
[0124] where:
[0125] S LS is the total lateral margin shift for show through error;
[0126] LW is the lateral width of the sheet; and
[0127] f 1L is the lateral first pass shrink rate.
[0128] As with the process direction analysis performed in step S 4400 , in step S 4600 , the distribution of this margin shift between the amount that will be applied to shift the first side image and the amount that will be applied to shift the second side image in the lateral direction is determined. Then, in step S 4700 , operation returns to step S 5000 . In various exemplary embodiments of the systems and methods according to this invention, the first side image is shifted toward the inboard edge of the sheet to compensate for show through error in the lateral direction. The lateral margin shift for the first side can be expressed as:
S LS1 =S LS *w (14)
[0129] where:
[0130] S LS1 is the first side lateral margin shift for show through error;
[0131] S LS is the total lateral margin shift for show through error; and
[0132] w is the proportion of the total lateral image shift to be applied to the first side image.
[0133] The total margin shift can be distributed in any suitable manner. In various exemplary embodiments of the systems and methods according to this invention, half of the margin shift is applied to shift the first side image and half of the margin shift is applied to shift the second side image, i.e. w equals 0.5. In this case, the margin shift applied to the first and second side images would thus be one-half of the lateral show through margin shift for side one and negative one-half of the lateral show through margin shift for side two.
[0134] In various exemplary embodiments of the systems and methods according to this invention, the second side image is shifted toward the outboard edge of the sheet to compensate for show through error in the lateral direction. The lateral margin shift for the second side can be expressed as:
S LS2 =−S LS *(1− w ) (15)
[0135] where:
[0136] [0136] LS2 is the second side lateral margin shift for show through error;
[0137] S LS is the total lateral margin shift for show through error; and
[0138] w is the proportion of the total lateral image shift to be applied to the first side image.
[0139] As with determining residual magnification error, it is not practicable to determine the lateral margin shift for every single sheet that is printed. Accordingly, general or default assumptions about the general sheet of paper can be made. In various exemplary embodiments, assumptions are made with regard to various types of paper. Thus, a different lateral margin shift can be applied for each type of paper being used. Assumptions about the lateral first pass shrink rate of a type of paper can then be stored in the non-volatile memory of a printer.
[0140] In various exemplary embodiments, all values needed to determine the various margin shifts, outlined above in Eqs. (9), (11), (12), (14) and (15), can be determined during the setup operation and stored in the non-volatile memory of the printing device. In various other exemplary embodiments, the measurements and determinations can be made at least in part by the user. In various exemplary embodiments, values for the lateral width, the process length, and the weight of a sheet of paper can be obtained on a sheet by sheet basis to make adjustments to margin shifts associated with the various types of sheets.
[0141] According to this invention, step S 5000 , in which the margin shift is applied, includes applying the second side process registration margin shift S RP2 and each of the lateral and process, first and second side magnification margin shifts S LS1 , S LS2 ,S PS1 and S PS2 to shift the positions of the first side and second side images on the first and second sides of the sheet, respectively, to reduce show through. As with determining the margin shifts, the margin shifts can be applied in any sequence, simultaneously or any combination thereof. Applying the margin shifts can include any manual or automated process of manipulating the sheet or printing apparatus to achieve the desired margin shifts.
[0142] [0142]FIG. 6 is a functional block diagram of one exemplary embodiment of the control system 200 according to this invention, usable to generate and apply the margin shifts discussed above, and to controllably output the shifted image data to an image forming engine 300 based on the determined margin shifts. As shown in FIG. 6, the control system 200 includes an input/output interface 215 , a controller 220 , a non-volatile memory 230 , a system memory 235 , a setup circuit or routine 240 , a residual magnification error determining circuit or routine 250 , a margin shift determining circuit or routine 260 , and a margin shift applying circuit or routine 270 , interconnected by a data/control bus or the like 280 . One or more input devices 205 are connected by a link 290 with the input/output interface 215 .
[0143] As shown in FIG. 6, each of the system memory 230 and the non-volatile memory 235 can be implemented using either or both of alterable or non-alterable memory. In FIG. 6, the alterable portions of the memories 230 or 235 are each, in various exemplary embodiments, implemented using static or dynamic RAM. However, the alterable portions of each of the memories 230 and 235 can also be implemented using a floppy disk and disk drive, a writable optical disk and disk drive, a hard drive, flash memory or the like. In FIG. 6, for each of the system memory 230 and the non-volatile memory 235 , the non-alterable portions of the memories 230 and 235 are each, in various exemplary embodiments, implemented using ROM. However, the non-alterable portions can also be implemented using other non-volatile memory, such as PROM, EPROM, EEPROM, an optical ROM disk, such as a CD-ROM or a DVD-ROM, and disk drive, or other non-alterable memory, or the like.
[0144] Thus, for each of the memories 230 and 235 , those memories 230 and 235 can each be implemented using any appropriate combination of alterable, volatile, or non-volatile memory or non-alterable or fixed memory. The alterable memory, whether volatile or non-volatile, can be implemented using any one or more of static or dynamic RAM, a floppy disk and disk drive, a writable or re-writable optical disk and disk drive, a hard drive, flash memory or the like. Similarly, the non-alterable or fixed memory can be implemented using any one or more of ROM, PROM, EPROM, EEPROM, an optical ROM disk, such as a CD-ROM or a DVD-ROM disk and disk drive or the like.
[0145] It should be appreciated that the control system 200 shown in FIG. 6 can be implemented as a portions of a programmed general purpose computer used to control the overall operation of the image forming engine. Alternatively, the control system 200 can be implemented using an ASIC, a FPGA, a PLD, a PLA, or a PAL, or using physically distinct hardware circuits, such as discrete logic elements or discrete circuit elements. The particular form the controller 220 shown in FIG. 6 will take is a design choice and will be obvious and predictable to those skilled in the art.
[0146] Alternatively, the control system 200 can be implemented as a portion of a software program usable to form the overall control system of the image forming engine. In this case, each of the controller 220 and the various circuits or routines 240-270 can be implemented as software routines, objects and/or application programming interfaces or the like.
[0147] In general, the one or more input devices 205 will include any one or more of a keyboard, a keypad, a mouse, a track ball, a track pad, a touch screen, a microphone and associate voice recognition system software, a joy stick, a pen base system, or any other known or later-developed system for providing control and/or data signals to the control system 200 . The input device 205 can further include any manual or automated device usable by a user or other system to present data or other stimuli to the control system 200 .
[0148] The link 290 can be any known or later-developed device or system for connecting the input device 205 to the control system 200 , including a direct cable connection, a connection over a wide area network or a local area network, a connection over an intranet, a connection over the Internet, or a connection over any other known or later-developed distributed processing network or system. In general, the link 290 can be any known or later-developed connection system or structure usable to connect the input device 205 to the control system 200 .
[0149] In operation, the user operates the control system 200 to cause the image forming engine to print a registration test image, such as that shown in FIG. 1, on the first and second sides of a sheet. The user then operates the input device 205 to submit measurements obtained from the registration test image to the control system 200 . The measurements can include, but are not limited to, image squareness, image skew, lateral magnification, process magnification and image-to-paper position. The various measurements obtained from the registration test image are then stored by the controller 220 in one or both of the non-volatile memory 230 and the system memory 235 .
[0150] The controller 220 then accesses at least some of the measurements stored in one or both of the non-volatile memory 230 and the system memory 235 and supplies the accessed measurements to the setup routine or circuit 240 . The setup routine or circuit 240 , under control of the controller 220 and in cooperation with the image forming engine 300 , adjusts the photoreceptor belt or drum speed and/or the pixel clock frequency as necessary to adjust for the average of the first side and second side magnification errors. Upon completion of the setup operation performed by the setup routine or circuit 240 , the controller 220 stores the data generated by the setup circuit or routine 240 , including but not limited to the nature and extent of the adjustments to the pixel clock frequency and/or the photoreceptor belt or drum speed, in one or both of the non-volatile memory 230 or the system memory 235 . The adjustment data is then output under the control of the controller 220 through the input/output interface 215 by the link 290 and the data/control bus or the like 290 to the image forming engine 300 .
[0151] The controller 220 then provides at least some of the data stored in one or both of the non-volatile memory 230 or the system memory 235 to the residual magnification error determining circuit or routine 250 . The residual magnification error determining circuit or routine 250 , under control of the controller 220 , determines first pass shrink rates and an amount of residual magnification error. Upon completion of the residual magnification error determining operation by the residual magnification error determining circuit or routine 250 , the controller 220 stores at least the values for first pass shrink rates and the amount of residual error determined by the residual magnification error determining circuit or routine 250 in one or both of the non-volatile memory 230 or the system memory 235 .
[0152] The controller 220 then accesses at least some of the data stored in one or both of the non-volatile memory 230 or the system memory 235 and provides the accessed data to the margin shift determining circuit or routine 260 . The margin shift determining circuit or routine 260 , under the control of the controller 220 , determines margin shifts to reduce registration error and to reduce show through error. Upon completion of the margin shift determining operation by the margin shift determining circuit or routine 260 , the controller 220 then stores the values for registration margin shift and process and lateral show through margin shifts and first and second sides determined by the margin shift determining circuit or routine 260 in one or both of the non-volatile memory 230 or the system memory 235 .
[0153] The controller 220 then accesses at least some data from one or both of the non-volatile memory 230 or the system memory 235 and provides the accessed data to the margin shift applying circuit or routine 270 . The margin shift applying circuit or routine 270 , under the control of the controller 220 , generates data usable by the image forming engine 300 and/or by the controller 220 , or another controller (not shown) that controls supplying image data or desired paper position to the image forming engine 300 , to adjust the image position by applying the margin shifts determined by the margin shift determining circuit or routine 260 . Thus, in various exemplary embodiments, the margin shift applying data is output, under the control of the controller 220 , through the input/output interface 215 over the link 290 to the image forming engine 300 , or to the other controller. Alternatively, the controller 220 transfers the margin shift applying data from the margin shift applying circuit or routine 270 into the one or both of the non-volatile memory 230 or the system memory 235 for later use by the controller 220 in modifying the image data based on the determined margin shifts.
[0154] While this invention has been described in conjunction with the specific embodiments above, it is evident that many alternatives, combinations, modifications, and variations are apparent to those skilled in the art. Accordingly, the preferred embodiments of this invention, as set forth above are intended to be illustrative, and not limiting. Various changes can be made without departing from the spirit and scope of this invention. | The relationship between first and second side images is evaluated to determine how the position of the paper and/or the size and arrangement of an image can be manipulated to compensate for paper shrinkage caused by fusing. Show through is reduced by performing setup to adjust a pixel clock frequency and/or a photoreceptor speed, determining a residual magnification error, determining margin shifts to compensate for the residual magnification error, and applying the margin shifts. Paper shrink effects on registration can be compensated for using determinations made during a typical printer setup. Show through errors can be reduced without using a paper conditioner to pre-shrink or re-wet the paper. In simplex and duplex printing, the show through errors worsen as the image moves away from the registration edge. Using information obtained during setup, a margin shift is determined that results in a significant reduction in the maximum show through for each image. | 7 |
BACKGROUND OF THE INVENTION
This invention pertains to pressing machines and, in particular, to pressing machines for garments or the like.
Conventional garment pressing machines typically utilize a pivotally mounted lever or arm (y-piece) to move a pressing head into forceful engagement with a pressing surface or support (buck) holding the article to be pressed. In these machines it is customary to first pivot the arm so that the head is closely spaced from or in slight pressure engagement with the buck. Additional force is then applied to the arm so that the head exerts the necessary pressure (e.g., several thousand pounds) on the buck to press the article.
Various pressing machine configurations have been proposed to achieve this pressing action. U.S. Pat. No. 1,797,720 discloses one type machine in which an actuating air cylinder acting through a toggle arrangement provides the initial pivoting of the press arm. The toggle arrangement locks the arm and an expansible fluid filled chamber on the buck is then pressurized to provide the necessary pressing pressure between the head and buck. U.S. Pat. No. 1,797,757 discloses a similar press with an expansible buck, but with a modified arm arrangement. In this case locking of the arm is through engagement of a pawl and ratchet under the pressure created by the expansible buck. An expansible buck type press is also disclosed in U.S. Pat. No. 2,068,643.
In U.S. Pat. No. 3,877,161, on the other hand, the head, rather than the buck, is made expansible and is used to realize the desired pressing pressure.
A further pressing type machine is disclosed in U.S. Pat. No. 4,002,046. In this type machine, a cavity in the buck is selectively pressurized to cause pistons or controlled diaphragm members to urge the buck pressure plate against the pressing head.
Other pressing machine arrangements are also known wherein actuating air cylinders are used to realize both the initial arm pivoting and the desired pressing pressure. In this type of arrangement, a small-bore cylinder provides the initial pivoting under relatively little pressure, while a large-bore cylinder provides pressing action under relatively heavier pressure. Usually, the large-bore cylinder is located such that the cylinder goes over the bottom dead center at some point during the initial pivoting of the arm. In this way, the amount of stroke required of the large-bore cylinder to permit the full motion of the arm is reduced. However, the required stroke is still much longer than that which would be required to provide the slight additional movement of the arm to result in the desired heavy pressure. The large-bore cylinder must, therefore, consume a significant quantity of air which produces no useful result.
The necessity of using a large-bore long-stroke cylinder in the aforesaid pressing machine thus presents disadvantages from both an operational and economic point of view. Furthermore, the other described pressing machines suffer disadvantages of one type or another.
It is a primary object of the present invention to provide a pressing machine of an improved type.
It is a further object of the present invention to provide a pressing machine in which initial pivoting and pressing are realized in an operationally and economically efficient manner.
SUMMARY OF THE INVENTION
In accordance with the principles of the present invention, the above and other objectives are realized in a pressing machine in which the actuator for applying the required pressing pressure to the machine arm is disposed between the arm and a pivotally mounted link extending in spaced relationship to the arm. Initial pivoting of the arm and link with the actuator therebetween occurs before the application of force by the actuator. A latching mechanism prevents reverse pivoting of the link during force application, whereby the desired pressure is achieved. The latching mechanism is further arranged so as not to latch unless initial pivoting of the arm has been completed.
In the embodiment of the invention to be disclosed hereinafter, a further actuating means in the form of a small-bore long-stroke cylinder is used to provided initial pivoting, while the pressing actuator is in the form of a large-bore short-stroke actuator and, in particular, an inflatable rubber actuator.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and aspects of the present invention will become apparent upon reading the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates schematically, a pressing machine in accordance with the principles of the present invention;
FIGS. 2 and 3 show the pressing machine of FIG. 1 after initial pivoting of the machine arm and after application of pressing pressure to the arm.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, the pressing machine 1 comprises a frame 2 carrying a main shaft 3 on which is pivotally mounted arm 5 to pivot about point 4. The arm 5 carries at its forward portion 6, a pressing head 7. Application of force to the rearward portion 6a of the arm 5 brings the head 7 into engagement with a complementary pressing surface or buck 8 carrying the article to be pressed. The buck 8 is mounted on the frame 2 via a support 9.
In the present illustrative case, a counterbalance spring 11 attached to the arm 5 through a link 12 offsets the weight of the head 7 and causes it to remain in the up or fully opened position when no external force is applied to the arm 5. A swiveling control rod assembly 31, 31a is also attached to the arm 5 and connects to a shock absorber 32 which smooths out the motion of the arm 5 when opening and closing.
A link 14 pivotally mounted at one end 14a on the shaft 3 extends in spaced relationship below the arm portion 6a. An actuating means in the form of a small-bore long-stroke air actuating cylinder 15 connects to a secondary shaft 16 affixed to the other end 14b of the link 14. The cylinder 15 acts to initially pivot the assembly as will be discussed in more detail below.
Also pivotally mounted on the secondary shaft 16 is a latch 21 whose upper flat surface 21a extends forward of the shaft 16 above the link 14 and in the region between the link and the arm portion 6a. A biasing spring 22 is connected to face 21b of the latch 21 and to the link 14 forward of the shaft 16. The lower end 21c of the latch has a roller 21d for riding up the steeply inclined portion 41a of ramp surface 41 of latching member 17. The ramp surface 41 has a lesser inclined portion 41b at its upper end for locking the roller movement, as will be discussed hereinafter.
A further actuating means 18 in the form of a large-bore short-stroke actuator is situated above the latch surface 21a in the space between the link 14 and the arm portion 6a. The actuator 18 includes an air inflatable rubber tube 18a, similar to a small automobile tire, held between two supporting blocks 18b and 18c. These blocks engage the arm portion 6a and the latch surface 21a, respectively. Positioning of the actuator 18 is such that its center line is forward of the shaft 16, thereby permitting pivoting motion to be applied by the actuator to the latch 21.
A rubber bumper 33 is affixed to the top of the link 14 just rearward of the pivot point 4 and contacts the bottom of the arm 5 whenever the actuator 18 is not actuated. The bumper 33 establishes enough spacing between the arm 5 and link 14 that the tube 18a is never allowed to completely collapse, thereby leaving the latch 21 free to pivot slightly about the point 16.
Operation of the pressing machine 1 occurs in two stages. The first stage is depicted in FIG. 2 and results in an initial pivoting of the arm 5 so that the pressing head 7 is brought into adjacent confronting relationship with the buck 8. The second state is shown in FIG. 3 and results in engagement between the head 7 and buck 8 with the pressure or force required to carry out the desired pressing.
More particularly, in the first operating stage, air actuating cylinder 15 is operated and the cylinder rod 15a provides a pivoting force to the link 14 through the shaft 16. This force is also applied through the bumper 33 to the arm portion 6a. The arm 5 and link 14 are thereby pivoted to a predetermined or preselected position.
Operation of actuating cylinder is such that the pivoting force is sufficient to overcome the tension of spring 11 and the stroke of the cylinder is adjusted so that a position is reached which brings the head 7 closely adjacent, but spaced from the buck 8. Alternatively, the cylinder stroke could have been adjusted so that the head 7 engaged buck 8 under slight pressure. In any case, pivoting of the arm and link also brings the roller 21d up the portion 41a of the ramp surface 41 to a position shown in phantom lines on a level with or slightly above the lesser angled portion 41b. The latch 21 thus is in adjacent but unlatched position relative to the latch member 17. It should be noted that the latter member 17 could be made to be adjustable so as to permit downward or upward movement of the member. Such adjustable feature would enable adjustment of the latch member to account for changes in the thickness of the resilient padding of the buck as well as for changes in the amount of spacing between the buck and head upon initial pivoting.
Upon completion of this initial pivoting, the second stage of operation is carried out by pressurization of air actuator 18a causing a force to be exerted between the blocks 18b and 18c. This force, in turn, is transmitted to the arm portion 6a, as well as to the latch 21 and the link 14. The latch 21, due to the positioning of the actuator 18, is thereby caused to pivot bringing the roller 21d into engagement with the surface portion 41b of latch member 17, as shown in solid lines in FIG. 2 and in FIG. 3. Engagement of the roller 21d and surface portion 41b is sufficient to prevent movement of the roller 21d down such surface. Further pivoting of the latch 21 and reverse or counter pivoting of the link 14 thus does not occur. These two elements, the latch 21 and link 14, are therefore locked to the frame 2. As a result, the actuator force (this force might, for example, be approximately one ton), acts primarily upwardly against the arm portion 6a. This causes further pivoting of the arm 5 to bring the head 7 into engagement with the buck 8 with sufficient pressure to press the article.
When the air pressure to actuator 18 is terminated, the force exerted by the actuator ceases. The head and buck disengage and the roller 21d is now able to slide down the surface portions 41b and 41a. Further release by actuator 15, causes the entire assembly to reverse or counter pivot under the action of spring 11 bringing the assembly to its original starting position.
As can be appreciated, the present pressing machine has the attendant advantages of permitting the use of large-bore short-stroke and small-bore long-stroke actuators for effecting pressing engagement and initial pivoting, respectively, of the pressing assembly. As a result, air consumption is reduced to a minimum and the speed of operation is improved because there is virtually no non-essential chamber volume to fill.
Furthermore, pressing pressure cannot be exerted unless the assembly has completed its initial pivoting to place the arm and link at their preselected positions. Thus, for example, if the actuator 18 is pressurized before the initial pivoting occurs, then the link 14 and arm 5 will be spread apart before the roller 21d and surface portion 41b are positioned to engage. As a result, no engagement will occur between head 7 and buck 8 and the actuator 18 cannot cause exertion of pressing pressure between the buck and head. Similarly, if an obstruction, such as, for example, an operator's hand, is on the buck preventing completion of the initial pivoting, then the roller 21d will not be able to be moved into engagement with the surface portion 41b. As a result, pressurization of actuator 18 will result in movement of the roller down the surface portion 41a and reverse rotation of link 14. No pressing pressure will therefore be exacted between the buck and head.
In all cases, it is understood that the above-described arrangements are merely illustrative of the many possible specific embodiments which represent applications of the present invention. Numerous and varied other arrangements can readily be devised in accordance with the principles of the present invention without departing from the spirit and scope of the invention. | A garment pressing machine wherein a pivotable link is disposed in spaced relationship to the machine arm carrying the machine pressing head and an actuator is arranged between the link and arm to provide the necessary pressure for pressing. Initial pivoting of the arm and link with the actuator therebetween occurs before the application of force by the actuator. A latching mechanism prevents reverse pivoting of the link during force application and the desired pressing pressure is achieved. The latching mechanism is further arranged so as not to latch unless initial pivoting of the arm has been completed. | 3 |
BACKGROUND OF THE INVENTION
Uranium dioxide for the manufacturing of current light water reactor fuel is currently produced from the conversion of UF 6 , mainly based either on a dry- or a wet-conversion process. Several routes of the dry-conversion process have been revealed so far, and chemical procedures involved in those routes are similar. UF 6 is usually pyrohydrolyzed with steam to form UO 2 F 2 powder which is reduced to UO 2 directly by a hydrogen-steam mixture, or is calcined in air to U 3 O 8 first and then reduced to UO 2 with a hydrogen-steam gas. In the wet-conversion process, vaporized UF 6 is hydrolyzed with water to form an aqueous UO 2 F 2 -HF solution, from which ammonium diuranate (ADU) or ammonium uranyl carbonate (AUC) is precipitated with ammonia water or ammonium carbonate, respectively. After filtration, ADU or AUC is calcined to UO 3 , which is then reduced to UO 2 with a hydrogen-steam gas. According to the chemical compositions of the precipitates, it is called an ADU process or an AUC process.
It is recognized that the UO 2 powder produced from the wet-ADU process possesses excellent powder characteristics required for pelletizing and sintering, and gives good microstructure to the sintered pellet. Although the ADU process is widely used currently, it is plagued by some inherent drawbacks. For example, in the conventional ADU process, such as that disclosed in the U.S. Pat. Nos. 3,394,997 and 3,998,925, UF 6 is hydrolyzed with water to form an aqueous solution containing 100 to 200 g/l of uranium and 0.4 to 0.8 mol/l of hydrogen fluoride. As ADU is precipitated from this solution, a pasty slurry is obtained and several tens of liters of the fluoride-containing liquid filtrate is thus generated for the production of 1 kg UO 2 . This introduces a serious problem of liquid waste disposal to the conventional ADU process. Moreover, because ADU is a kind of slimy cake, the process also involves a complicated filtration operation.
After a series of studies on the formation of ADU, it was found that ADU is formed simultaneously as soon as fine droplets of a concentrated solution of an uranyl compound are introduced into an ammonia gas stream, and the fluorine content of the UO 2 powder consequently produced using uranyl fluoride solution as a feed can be lower than 50 ppm. Therefore, instead of being precipitated from a dilute solution of uranyl compounds with ammonia water, ADU is prepared in particle form directly by introducing atomized droplets of a concentrated solution of uranyl compound into an ammonia gas stream in the novel process disclosed herein. The generation of the fluoride-containing liquid filtrate in converting uranyl fluoride to UO 2 is thus avoided, and filtration operation is no longer necessary. The process is thus greatly simplified.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a process generating no liquid filtrate and involving no tedious filtration operation for converting UF 6 or uranyl compounds to UO 2 via ADU. Due to the simple process variables involved in this new process, the UO 2 powder produced inherently possesses much higher consistency in quality than those produced with the conventional wet-ADU process.
To achieve its object, this invention provides a process for converting UF 6 to UO 2 powder comprising the steps of
(a) pyrohydrolyzing UF 6 with steam to obtain UO 2 F 2 powder;
(b) dissolving the said UO 2 F 2 powder in water to form an aqueous uranyl solution;
(c) atomizing the said aqueous solution into a gas stream of ammonia gas or ammonium hydroxide to prepare wet ADU particles;
(d) drying and calcining the said ADU particles directly to UO 3 or U 3 O 8 , or their mixture;
(e) reducing the said calcined particles to UO 2 with hydrogen or hydrogen-steam gas.
Accordingly, the present invention also provides a process for converting other uranyl compounds which form ADU with ammonium hydroxide, such as uranyl nitrate, uranyl sulfate, uranyl chloride, and etc., to UO 2 , comprising dissolving the uranyl compound in water as the first step and the foregoing steps of (c) to (e), whether or not additional metal species is incorporated into the aqueous solution of uranyl compound.
Instead of precipitating ADU from diluted uranyl solution with ammonia water in the conventional wet-ADU process, in the present invention, ADU is made by reacting gaseous ammonia or ammonium hydroxide vapor with a rather concentrated solution of uranyl compound. Basically, uranyl solution of any concentration can be used to prepare the ADU powder directly with the present invention, but only from those with high uranium concentration can the ADU be obtained as a divided wet particle rather than a slimy slurry. Nevertheless, dry ADU particles can be obtained directly in all cases by heating the wet ADU particle before settling, just as is usually done in spray drying. The particle thus obtained is of easy-easy-handling and free flowing. No filtration operation is involved and no liquid filtrate is generated in the present invention. The only liquid effluent coming out of the ADU preparation is a limited amount of water condensate recovered in the drying of ADU which it is free from uranium and is re-usable in the dissolution of UO 2 F 2 powder.
DESCRIPTION OF THE INVENTION
In conducting this invention, UF 6 in a cylinder is vaporized by heating in a water bath. The vapor is then introduced to a tube reactor, where it is pyrohydrolyzed with steam to carry out the reaction:
UF.sub.6 +2H.sub.2 O=UO.sub.2 F.sub.2 (HF).sub.n +(4-n)HF (1)
With a careful control of the flow rates of UF 6 and steam, finely divided UO 2 F 2 powders are obtained and collected at the bottom of the reactor. HF gas produced in reaction (1) may be neutralized in an alkali scrubber or recovered as a by-product after passing through a sintered-metal filter assembly.
The UO 2 F 2 powder obtained is dissolved in de-ionized water to prepared UO 2 F 2 solution. The solution is then atomized to form very small liquid droplets with an atomizer, such as: an impingement type nozzle, or a single-fluid nozzle, or a double-fluid nozzle, or an ultra sonic atomizer, on the top of a spray column. To the bottom of the column, ammonia gas is introduced to react with the liquid droplets of UO 2 F 2 as follows: ##EQU1## As shown, ammonia gas is absorbed by water in the droplets to form NH 4 OH, which then reacts with UO 2 F 2 to form ADU following reaction (3).
It is generally recognized that there are four types of ADU, i.e., type I, II, III, and IV, with the value of x expressed in reaction (3) equal to 0, 1/3, 1/2, and 2/3, respectively. Except type I, all other types of ADU may be included in the product of the present invention with their molar ratios depending on the operating conditions, such as UO 2 F 2 concentration in feed solution; the pressure of ammonia gas; the drop size of the aqueous solution of UO 2 F 2 ; and the resident time. Generally, a high pressure of ammonia gas is good for the formation of the high type ADU. However, too high a pressure may cause some operational troubles. A small droplet size of the uranyl compound solution will increase the rate of the formation of ADU, and will be good for the formation of the high type ADU too. However, a droplet too small in size may cause some problems in separating ADU from gas stream. Additional heat may be applied to increase the reaction temperature to facilitate the formation of ADU, and to accomplish a quick removal of the moisture from the ADU product. Ammonium uranyl fluoride (AUF) is a precursory product in the reaction, and it may exist in the ADU product, when a feed solution having a very high concentration of uranium is used, or when the ammoniation is not sufficiently done. Nevertheless, the presence of AUF in the ADU mixture will not give any trouble in converting all the uranium species to UO 2 , since AUF, as well as ADU, is also decomposed to form uranium oxide on calcining.
The formation reaction of ADU is exothermic, therefore, part of the water in the liquid UO 2 F 2 droplets is vaporized during the formation of ADU. Meanwhile, some of the water becomes a constituent part of ADU. Therefore, a feed solution of UO 2 F 2 having an uranium concentration higher than 500 g/l, or preferably higher than 600 g/l, will give wet finely divided ADU particles in the reaction without applying additional heat. When a less concentrated feed solution is used, the ADU product obtained is no longer divided particles, but is paste-like. Nevertheless, the stream of the wet ADU particles can be heated before settling, so as to remove the moisture to obtain a free flowing dry powder, directly, just as the way usually done in a spray drying. It is preferrable, for simplifing the operation, to carry out the drying and the calcining steps together in a drying-and-calcining step at 300° to 750° C., or preferably at 400° to 600° C. Ammonium fluoride vaporized in the step is separated from water vapor by condensing it at a temperature ca. 105° C. The ammonium fluoride thus recovered is free from uranium, and is readily a valuable resource of fluorine. The water vapor is condensed and recycled for the dissolution of UO 2 F 2 powder. Clearly, no liquid filtrate is generated, and no complicated filtration operation is involved in the preparation of ADU, if the method of the present invention is used.
Produced under an atmosphere of nitrogen gas, the calcined product is essentially UO 3 , which is then reduced to UO 2 in a reduction furnace with a hydrogen-steam mixture at 500° to 850° C., or preferably at 550° to 650° C. In the reduction furnace, the residual fluoro species interact with steam to form HF and then leave the product. The UO 2 thus obtained is a finely divided powder having low fluorine content, high activity, and good sinterability.
Besides uranyl fluoride, other uranyl compounds such as uranyl nitrate, uranyl chloride, uranyl sulfate, and etc., can also be used to prepare ADU with the present method. Furthermore, the present invention is also applicable to the preparation of mixed metal oxides containing uranium, for instance, the mixed oxide of uranium and gadolinium can be made, if a solution containing uranyl nitrate and gadolinium nitrate is used as the feed solution.
The following examples illustrate the present invention. It is understood that they are only exemplary and do not limit the scope of the present invention.
EXAMPLE 1
UF 6 in an 8A cylinder was loaded in an electrically heated water bath equiped with a stirrer. The temperature of water in the bath was automatically controlled at 90° to 95° C. and was kept homogeneous by stirring. The UF 6 in the cylinder was melted and vaporized to give a final pressure of ca. 30 psig. Then, the vapor was introduced into the top part of an Inconel tube reactor of 4" diameter through a mass flowmeter. Steam having a pressure of 10 psig was also introduced to the reactor from the reactor wall side at a position below and near to the inlet point of UF 6 . The flow rate of steam was regulated with a needle type metering valve. The whole piping system, as well as the tube reactor body, was heated with heating mantles to maintain a constant temperature of 125° C. The steam entering the reactor was thus super-heated and became completely dry. The flow rate of UF 6 vapor was 300 g/hr and steam was 60 g/hr. The UO 2 F 2 powder formed in the reactor was finely divided and settled at the bottom of the reactor. Hydrogen fluoride gas produced in the reaction was filtered with a sintered-metal (Inconel 600) filter assembly and was sent to an alkali scrubbing system. After 5 hours, feeds of UF 6 and steam were ended. The feed line of UF 6 and the reactor were purged with nitrogen gas, and the UO 2 F 2 powder produced was discharged to a container.
The foregoing UO 2 F 2 powder was dissolved in de-ionized water to give a solution containing 1138 g/l of uranium with a density of 2.26 g/ml. Four liters of the solution was put in an Inconel pot, which was then pressurized to 75 psig with nitrogen gas. The UO 2 F 2 solution coming from the pot through a bottom tube was atomized to form very small liquid droplets with an impingement type nozzle at the top of a spray column. The column had been prepurged with ammonia gas before use. An excess amount of ammonia gas was supplied continuously from the bottom of the column simultaneously. The liquid UO 2 F 2 droplets were converted to ADU particles having a brown yellow color as soon as it contacted with ammonia gas. The excess ammonia gas and the water vapor leaving the column through a top exit pipe were sent to a water scrubber. The UO 2 F 2 solution was used up completely in 4 minutes, then, the supply of ammonia gas was stopped immediately, and the column was purged with nitrogen gas. The product collected in a bottom tray in the column were wet but loosely divided granules, which, identified with x-ray diffractometry, were found to contain essentially ADU, AUF, and ammonium fluoride. No liquid filtrate was generated and no filtration operation was involved in the operation.
A sample weighted 169.5 g taken from the foregoing ADU product, having a moisture content of 25.6 wt % and an uranium content of 68.34 wt % (dry basis), was put in an Inconel tray with a bed depth of 1 cm. The tray was loaded inside a retort in an electrically heated furnace. The ADU mixture was converted to UO 2 with the following steps: (1) The bed temperature of ADU was increased from room temperature to 600° C. in 145 minutes; a nitrogen gas with a flow rate of 30 SCFH was introduced from the beginning of heating. (2) A steam with a mass flow rate of 12.79 g/min and a hydrogen gas with a volume flow rate of 30 SCFH were introduced immediately as temperature reached 600° C.; then, the bed temperature was kept isothermally for 90 minutes, and was then decreased to 540° C. in 40 minutes; the supply of the hydrogen gas was ended at this temperature. (3) The bed was cooled to 50° C., and the steam supply was ended at the moment when the temperature was lowered to 200° C. (4) Kept the temperature isothermally at 50° C., and a nitrogen gas containing 10% air was introduced for 60 minutes to stabilize the UO 2 powder. Then, the furnace was shut down and the product was cooled to room temperature and discharged.
The UO 2 powder thus obtained was 97.5 g, which gives a recovering rate of 99.7%. The powder was found to have a good flowability, a fluorine content 32 ppm, an O/U ratio 2.034, a bulk density 2.15 g/ml, and a specific surface area 2.2 m 2 /g.
EXAMPLE 2
The procedure of example 1 was repeated except that the concentration of uranium in the UO 2 F 2 solution for preparing ADU was 500 g/l. The ammoniation product thus prepared was found to contain essentially ADU, ammonium fluoride, and a small amount of AUF. The UO 2 powder thus obtained has a fluorine content 22 ppm, an O/U ratio 2.041, a bulk density 1.71 g/ml, and a specific surface area 2.2 m 2 /g.
EXAMPLE 3
The procedure of example 1 was repeated with the exceptions that: (1) uranium concentration in the UO 2 F 2 solution for preparing ADU was 634 g/l; (2) the drying and the calcining of the ADU product were carried out with a temperature profile of increasing from room temperature to 550° C. in 130 minutes, and then kept the temperature isothermally at 550° C. for 60 minutes; (3) the reduction was carried out at a constant temperature of 550° C. for 60 minutes and, then, by decreasing the temperature from 550° C. to 500° C. in 30 minutes. The UO 2 powder thereof made has a fluorine content 45 ppm, an O/U ratio 2.048, a bulk density 2.22 g/cm 3 , and a specific surface area 3.7 m 2 /g.
EXAMPLE 4
An uranyl nitrate solution containing 502 g/l uranium was prepared by dissolving pure uranyl nitrate in a de-ionized water. The procedures of example 1 were repeated to convert the uranyl nitrate to UO 2 powder with the exceptions that: (1) the impingement nozzle was replaced by an ultra sonic atomizer in atomizing the solution; (2) the drying and the calcining of ADU were carried out with a temperature profile of increasing from room temperature to 500° C. in 85 minutes, and then kept this temperature at constant for 60 minutes; (3) the reduction was carried out with a temperature profile of increasing from 500° C. to 600° C. in 35 minutes, then kept the temperature isothermally for 100 minutes, and finally decreased the temperature from 600° C. to 500° C. in 50 minutes. The UO 2 powder obtained is free flowing, it was found to have an O/U ratio 2.106, a specific surface area 4.9 m 2 /g, and a bulk density 0.4 g/ml.
EXAMPLE 5
A solution containing 502 g/l uranium and 30.12 g/l gadolinium was prepared by dissolving uranyl nitrate in a de-ionized water and dissolving gadolinium oxide in a nitric acid solution, and then mixed up. Following the procedures of example 4, the mixed solution of uranyl nitrate and gadolinium nitrate was converted to a gadolinium-uranium oxide with the exceptions that: (1) the drying-calcining operation was done with a temperature profile of increasing from room temperature to 500° C. in 100 minutes, and then kept the temperature at constant for 60 minutes; (2) the reduction operation was done with a temperature profile of increasing the temperature from 500° C. to 650° C. in 45 minutes, then kept this temperature at constant for 100 minutes, and decreased to 500° C. in 80 minutes; (3) the cooling profile comprised decreasing the temperature from 500° C. to 60° C. in 195 minutes; and (4) the stabilization of UO 2 powder was carried out at 60° C. The U-Gd oxide thus obtained was found to have an oxygen/metal molar ratio 2.187, a bulk density 0.32, and a specific surface area 10.5 m 2 /g. | ADU (ammonium diuranate) is prepared in particle form directly by reacting ammonium gas with liquid droplets of atomized uranyl compound solutions. Generation of liquid filtrate is prevented by using concentrated solutions of uranyl compounds as feed solutions, or drying the wet ADU particles formed before their settlement when a feed of low concentration is used. The ADU particle thus prepared is finely divided and easy-handling. No filtration operation is necessary in the preparation. The UO 2 powder consequently obtained after calcining and reduction has consistent quality from batch to batch and has good pelletizing and sintering properties. Uranium dioxide with low fluorine content can be prepared from uranyl fluoride solution. Gadolinium-uranium oxide can also be prepared with the present method using an aqueous mixture of gadolinium nitrate and uranyl nitrate as a feed solution. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This a continuation-in-part of copending application Ser. No. 429,028 filed Dec. 19, 1973 now abandoned.
BACKGROUND OF THE INVENTION
As is well known, arylamines have been made in a variety of ways including reduction of the corresponding nitro compound, reaction of a chloro compound with ammonia either alone or with catalysts such as copper salts, reaction of phenols with ammonia and zinc chloride at an elevated temperature and by the well-known Hofmann amide rearrangement with a hypohalite or halogen and a base. For some time, more direct methods of producing arylamines have been sought.
More recently, Canadian Pat. No. 553,988 issued on Mar. 4, 1958 to Thomas describes a one-step process for the production of aromatic amines. One embodiment comprises contacting a mixture of benzene, ammonia and oxygen in the vapor phase with a platinum catalyst maintained at a temperature of about 1000° C. In another embodiment, a mixture of benzene and ammonia is contacted in the vapor phase with a reducible metal oxide such as nickel oxide at a temperature of about 100° C to 1000° C. The benzene is directly converted to aniline as represented by the equation
C.sub.6 H.sub.6 + NH.sub.3 + MO → C.sub.6 H.sub.5 NH.sub.2 + H.sub.2 O + M,
wherein M represents the metal and MO represents the oxide thereof.
U.S. Pat. No. 2,948,755 issued on Aug. 9, 1960 to Louis Schmerling describes the preparation of aromatic amines by reacting an aromatic compound such as benzene with anhydrous ammonia in the presence of a compound of a group VI-B metal such as molybdenum, tungsten or chromium and a promoter consisting of an easily reducible metallic oxide such as an oxide of copper, iron, nickel, silver or gold at a temperature in the range from about 200° to 600° C. The easily reducible metallic oxide is stated to perform as a hydrogen acceptor to thus remove the by-product hydrogen produced, causing the reaction to proceed in the desired direction.
An earlier reference, J. B. Wibaut, Berichte, 50, 541-6 (1917), reported the synthesis of aniline by passing benzene and ammonia through an iron tube packed with reduced nickel, iron, and asbestos at a temperature in the range of 550° to 600° C.
While the methods of these references do provide direct processes for the production of the aromatic amine, they do so in low conversions and yields of the aromatic compound to aromatic amine.
In an attempt to obviate these problems, it has been proposed to carry out the reaction betwen ammonia and the aromatic compound in the presence of a conditioned nickel/nickel oxide/zirconium oxide cataloreactant, so named because it acts as a catalyst as well as a reactant in the direct amination of an aromatic compound with ammonia. Prior to use in the reaction the cataloreactant is conditioned. That is, the nickel oxide component of the cataloreactant is partially reduced to elemental nickel in a reducing atmosphere such as hydrogen. The elemental nickel formed by this process is partially oxidized back to nickel oxide in an oxidizing atmosphere such as oxygen, air or water.
It has also been proposed to improve conversions obtained with the conditioned cataloreactant by ammonia treatment immediately before use in the reaction of the aromatic compound with ammonia. In spite of the improved results achieved using the conditioned cataloreactant as well as those which have been subjected to an ammonia treatment, the demands of production make it necessary to continue to search for improved systems which yield still higher conversion rates.
SUMMARY OF THE INVENTION
In accordance with this invention, it has been found that improved conversions of aromatic compounds to aromatic amines and longer cataloreactant life can be achieved when the aromatic compound is reacted with ammonia at a temperature of from about 150° C. to about 500° C. at a pressure of from about 10 to about 1000 atmospheres in the presence of a conditioned Ni/NiO/ZrO 2 cataloreactant containing an oxide of lanthanum, samarium, holmium, europium, erbium, praseodymium, neodymium, terbium, ytterbium, dysprosium, yttrium or mixtures thereof as a dopant. The cataloreactant containing one or more of the dopants of this invention may also be treated with ammonia immediately before use in the amination reaction.
The term dopant refers to an oxide of lanthanum, samarium, holmium, europium, erbium, praseodymium, neodymium, terbium, ytterbium, dysprosium, yttrium or mixtures thereof as an adjuvant which gives the cataloreactant composition of this invention its unique properties as more fully described hereinafter.
Thus in the process of the present invention, an aromatic compound selected from anthracene; phenanthrene; quinoline; isoquinoline and compounds having the formula (X) m (Y) n wherein X is benzene or pyridine, m is 1 or 2, n is 0, 1 or 2, and Y is alkyl having one to six carbon atoms, halogen, nitrile, hydroxy, CONH 2 , alkoxy having one to six carbon atoms, aryloxy, amino and aralkyl, with the proviso that when Y is aryloxy, a secondary or tertiary arylamine or an aralkyl, n is 1 and when n is 2, the substituents Y may be the same or different, is aminated by reacting ammonia with said aromatic compound at a temperature of from about 150° C. to about 500° C. and at a pressure of from about 10 to 1000 atmospheres, in the presence of a conditioned Ni/NiO/ZrO 2 cataloreactant with a mole ratio of nickel to nickel oxide of 0.001 to 10, the improvement has been found which comprises carrying out the reaction in intimate molecular contact with said conditioned cataloreactant containing a molar ratio of 0.0001 to 0.05 of a dopant to total nickel, wherein said dopant is selected from an oxide of lanthanum, samarium, holmium, europium, erbium, praseodymium, neodymium, terbium, ytterbium, dysprosium, yttrium and mixtures thereof.
DETAILED DESCRIPTION OF THE INVENTION
A. The Cataloreactant-Dopant System
The reaction between the aromatic compound and ammonia is an equilibrium reaction represented by the following equation using benzene as an example: ##STR1## The mole ratio of ammonia/aromatic compound is preferably from 0.1 to 20, most preferably from 1.0 to 10, although any desired ratios may be employed.
The cataloreactants of the invention are nickel/nickel oxide/zirconium oxide compositions which function both as catalysts and as reactants in the amination of the aromatic compound. Specifically, the elemental nickel component catalyzes the reaction between the aromatic compound and ammonia while the nickel oxide component is the reactant. The nickel oxide is reduced to elemental nickel by the hydrogen formed during the reaction between the aromatic compound and ammonia. The zirconium oxide component is a support-promoter which enhances the catalytic properties of the cataloreactant and prevents reduced nickel crystallite coalescence by physically separating the crystallites. The preferred mole ratio of nickel to nickel oxide is from 0.001 to 10, most preferably from 0.01 to 1. The mole ratio of the total nickel in the form of nickel and nickel oxide in the cataloreactant to zirconium oxide expressed in terms of total nickel:zirconium is from 0.1 to 100, preferably from 0.3 to 20.
The cataloreactant of this invention is characterized by the fact that the size of the nickel crystallites varies from about 50 to 1000 A, preferably 80 to 250 A. If the crystallites are too large the activity of the cataloreactant is too low, and if the crystallites are too small unwanted side reactions take place because of overactivity.
The dopants of this invention are employed at a molar ratio of dopant to total nickel in the form of nickel and nickel oxide in the cataloreactant of from 0.0001 to 0.05. The use of the dopant increases the reactivity and prolongs the life of the cataloreactants of this invention. Such a result is entirely unexpected, particularly in view of the findings reported in a paper by Charcosset el al., published in the Journal of Catalysis, volume 22, pages 204-212, (1971) entitled "Increase of Reducibility of NiO by H 2 , Due to Pretreatment with Salt Solutions" which states that lanthanum has no positive effect on the rate of reduction of NiO.
On the other hand, lanthanum oxide has been used with nickel oxide to improve the rate of carbon monoxide oxidation with oxygen to carbon dioxide as reported by Zielinski and Wachowski in an article in volume 45, of Roczniki Chemii (pages 1701-1709 ) entitled "Changes in the Physic-Chemical and Catalytic Properties of Lanthanum-Doped NiO".
In the oxidation reaction of Zielinski el al. the nickel oxide functions as a catalyst in contradistinction to the situation in the instant case in which the nickel oxide functions as a reactant. Therefore, the nickel oxide is not reduced to elemental nickel in the Zielinski et al. reaction. Indeed, the lanthanum oxide combines with the nickel oxide to yield a catalyst having a greater surface area and increased sintering resistance, both of which would enhance the apparent catalytic activity of the nickel oxide catalyst. While the applicant does not wish to be bound by any precise theory of operation, studies have shown that the phenomenon which occurs in the instant case arises because the lanthanum oxide (dopant) enters into the zirconium oxide lattice structure. There is no detectable effect of the addition of lanthanum oxide (dopant) on the nickel oxide phase as determined using standard phase analysis techniques.
The cataloreactant-dopant systems of this invention may be prepared by any suitable method. Generally, the system is precipitated from a solution of a nickel, zirconium and dopant compound such as the nitrate salt, by addition of a solution of a base such as ammonium carbonate, sodium hydroxide, lithium hydroxide, potassium hydroxide, ammonium hydroxide, sodium carbonate, sodium bicarbonate, potassium carbonate and the like and mixtures thereof. Additionally any nickel, zirconium and dopant-metal salt or ester which can react with an oxygen source, such as oxygen, water or part of the salt anion to give oxides or hydrous ozides can be used.
After the precipitation of the components of the cataloreactant-dopant system in the form of the oxide or hydrous oxide, the precipitate is filtered, washed, dried, reduced with hydrogen and exposed to a suitable amount of air or oxygen or optionally water until the desired oxidation product is achieved. The resulting solid product has a surface area of at least 1.35 square meters per gram, preferably 1.35 to 300 square meters per gram, most preferably 20 to 200 square meters per gram.
In the conditioning operation, the cataloreactant-dopant system is reduced by being exposed to hydrogen at a temperature between about 300° C. and 600° C., preferably 350° C. to 425° C. The H 2 pressure can vary from 0.1 atmosphere to 10 atmospheres and preferably 0.1 to 2 atmospheres of pressure are employed. From about 10 percent to 90 percent of the nickel oxide and preferably 25 percent to 60 percent is reduced to metallic nickel in this step. The cataloreactant-dopant is then oxidized by treatment with a gas containing from about 0.1 percent to about 21 percent of oxygen, preferably 1 percent to 5 percent, at 30° C. to 800° C., preferably 100° C. to 500° C., and at 0.1 atmosphere to 600 atmospheres, preferably 1 to 300 atmospheres pressure, preferably for the length of time necessary to achieve a Ni/NiO mole ratio of from 0.001 to 10, preferably from 0.01 to 1.
Following this intermediate reduction-oxidation or conditioning step the cataloreactant-dopant system may be subjected to an ammonia treatment immediately before use in the amination reaction. Ammonia treatment can be carried out in several ways. If a batch reactor is used for the subsequent amination reaction, the reactor can be charged with the cataloreactant-dopant system, sealed, pressurized with ammonia and heated or the reactor can first be heated under a blanket of nitrogen and then a stream of ammonia can be passed over the cataloreactant-dopant system before introducing the ammonia and aromatic compound.
In a continuous reactor, the ammonia can simply be passed through the conditioned system before the start of a new synthesis cycle. For the sake of expediency in either a batch or continuous operation, the ammonia treatment is carried out at the temperature to be used in the subsequent reaction between the ammonia and the aromatic compound. It is to be understood, however, that the ammonia pretreatment can be carried out effectively at from about room temperature (approximately 20° C.) to about 500° C. Preferably an elevated temperature is employed, most preferably between 250° C. and 400° C. The quantity of ammonia to total nickel in the nickel/nickel oxide components of the cataloreactant system expressed as part/part on a molar basis ranges from about 0.01 to 20.0 and preferably 0.1 to 2.0.
The duration of the ammonia pretreatment ranges from about 1 to about 60 minutes and preferably from about 3 to about 20 minutes.
Pure ammonia can be used in the pretreatment of the cataloreactant. Alternatively, the ammonia can be diluted with inert gases such as nitrogen or helium. Generally there is no advantage in diluting the ammonia.
B. The Amination
The conditions under which the reaction between ammonia and the aromatic compound is carried out depend somewhat on the particular reactants. In general, temperatures of from about 150° C. to about 500° C. and pressures of from about 10 atmospheres to about 1000 atmospheres will be employed.
The amination process may be carried out either batchwise or in a continuous operation. In a batch-type operation the cataloreactants of this invention are used in such quantities that the weight ratio of the cataloreactant to the aromatic compound is from 0.01 to 10, preferably from 0.2 to 3. Any suitable apparatus in which the reactants can be combined and mixed such as an agitated autoclave or a pressure vessel may be used as the reactor. Preferably, the reactor is heated to the reaction temperature before the amination reactants are introduced. Once the reactor contains the cataloreactant-dopant, ammonia and the aromatic compound to be aminated, it is sealed and the reaction is allowed to proceed to the degree of conversion desired. Thereafter, the apparatus and the contents are cooled to room temperature or lower, excess NH 3 pressure is vented and the aminated aromatic reaction product is separated from unreacted aromatic compounds, the cataloreactant-dopant and by-products by conventional means such as distillation, crystallization, and the like.
In a continuous operation, the process may be carried out in any suitable apparatus that will permit a contact time between the amination reactants and the cataloreactant-dopant system of from two seconds to twenty minutes, preferably 30 seconds to eight minutes. Some such suitable apparatus would include fixed bed reactors or packed vessels or coils, into which the cataloreactant-dopant, ammonia and the aromatic compound can be charged and the aromatic compound and ammonia can be passed through a cataloreactant-dopant bed. A moving bed operation may also be employed in which the reaction bed and the reactants either pass cocurrently or countercurrently to each other. Still another type of continuous operation which may be employed is a fluidized bed or slurry type in which the cataloreactant-dopant composition is carried into the reactor as a slurry in one or more of the reactants.
In either the batch or continuous type of reactor the aromatic compound and the ammonia may be introduced separately or as a single mixed stream. The cataloreactant may either be regenerated intermittently or continuously with oxygen or an oxygen containing gas such as air optionally with water. If desired the aromatic compound and ammonia may be reacted in the presence of water.
In the preferred embodiment of this invention, the amination reaction is carried out at a temperature in the range of about 250° C. to about 500° C. and at a pressure ranging from about 30 atmospheres to about 700 atmospheres.
Any aromatic compound with which ammonia is miscible at the temperature and pressure of the reaction and which comes into intimate molecular contact with the cataloreactant-dopant system of this invention may be directly aminated with ammonia as described herein. By intimate molecular contact is meant that, at the reaction temperature and pressure, the molecules of each reactant are in contact, on a molecular basis, with the cataloreactant-dopant system of this invention. The aromatic compounds of this invention are selected from benzene, naphthalene, anthracene, phenanthrene, pyridine, quinoline, isoquinoline, mono or di substituted counterparts of any of them and compounds of the general formula (X) m (Y) n wherein X is benzene or pyridine, m is 1 or 2, n is 0, 1 or 2, and Y is selected from the group consisting of alkyl having one to six carbon atoms, halogen, nitrile, hydroxy, CONH 2 , alkoxy having one to six carbon atoms, aryloxy, amino and aralkyl with the proviso that when Y is aryloxy, a secondary or tertiary arylamine or an aralkyl, n is 1 and when n is 2, the substituent Y may be the same or different.
The preferred aromatic compounds of the present invention are selected from anthracene, phenanthrene, quinoline, isoquinoline and compounds of the formula (X) m (Y) n wherein X is selected from benzene and pyridine, m is 1 or 2, n is 0, 1 or 2 and Y is selected from alkyl having one to six carbon atoms, halogen, nitrile, hydroxy, CONH 2 , alkoxy having one to six carbon atoms, aryloxy, amino and aralkyl with the proviso that when Y is selected from aryloxy, a secondary or tertiary arylamine, and aralkyl, n is 1 and when n is 2 the substituent Y may be the same or different. The most preferred aromatic compounds of this invention are selected from the group consisting of benzene, toluene, pyridine and aniline.
In the definition of aromatic compounds of the above-general formula, representative examples of alkyl having one to six carbon atoms include methyl, ethyl, propyl, butyl, amyl and hexyl, including cycloalkyl such as cyclohexyl and cyclopentyl. Representative examples of halogen include fluoro and chloro. Representative examples of alkoxy having one to six carbon atoms include methoxy, ethoxy, propoxy, butoxy, and hexoxy including cycloalkoxy such as cyclohexoxy and cyclopentoxy. A representative example of aryloxy includes phenoxy. Representative examples of amino include primary, secondary and tertiary amino wherein the secondary amino groups contain alkyl having one to five carbon atoms or aryl such as phenyl. Representative examples of aralkyl include benzyl, including mono and dialkyl substituted aralkyls, wherein the alkyl groups contain one to five carbon atoms such as 2-methylbenzyl, 3-ethylbenzyl, 2,3-dimethylbenzyl and the like. Any of the substituents of Y described herein may be contained on the naphthalene, anthracene, phenanthrene, quinoline and isoquinoline nucleus.
Additional representative examples of the aromatic compounds of the present invention include biphenyl, bipyridine, 4,4'-dichlorobiphenyl, toluene, 0, m and p-xylene, aniline, chlorobenzene, fluorobenzene, 1,4-dichlorobenzene, ethylbenzene, anisole, 3-chloropyridine, 4-propylpyridine, hexylbenzene, 4-ethoxypyridine, phenoxy benzene, 4-phenoxypyridine, 3-aminopyridine, dimethylaminobenzene, 1,4-diaminobenzene, 2,4-diaminopyridine, 4-cyanopyridine, benzamide, benzonitrile, phenetole, o, m, p-dimethylbenzene, 1-chloronaphthalene, 2,5-dichloronaphthalene, 1-fluoroanthracene, 2-methylphenanthrene, diphenylmethane, 4-phenyl-2-methylpyridine, xylyl methyl benzene, 2(bisphenyl) propane, phenoxy benzene, N,N-diethylaminobenzene, 4-(N-phenylamino) pyridine, N-pentylaminobenzene, m-phenylenediamine, 3-amido-pyridine, 1-methyl-3-ethylbenzene, o-, m- and p-chloroaniline, o-, m- and p-chlorobenzonitrile, 2-chloro-4-cyanopyridine, p-methoxybenzamide; cyclohexylbenzene, 4-cyclopentylpyridine, 4-(N-methyl-N-phenyl) amino-pyridine, 3-hydroxy-pyridine, 1-hydroxy-3-chlorobenzene, 3-methoxy-quinoline, 5-cyanoisoquinoline, 4,4'-dicyanodiphenyl, 4-hydroxy-4'-fluorobiphenyl, 1,4-dichloroanthracene, 2,7-dihydroxy-phenanthrene, 1-chloro-5-amidonaphthalene, 5-phenoxy-isoquinoline, 3-chloro-4-fluoroquinoline, 2-pentoxy-7-hydroxyphenanthrene, 1-(2,3-dimethylphenyl) naphthalene, 1,4-dichloronaphthalene, methylisopropyl phenanthrene, 9,10-dichloroanthracene, anthradiamine, dihydroanthracene, 2,3-dimethylanthracene, 9-ethylanthracene, aminoquinoline, aminophenylmethylquinoline, benzoquinoline, chloroquinoline, dimethylquinoline, quinolinol, methoxyquinoline, α-methylquinoline, cyanoquinoline, 1-benzyl-N-methylisoquinoline, N-methyl pyridine, 3-benzylpyridine, 3,5-dimethylpyridine, 4-hydroxypyridine, 3-methyl-5-ethylpyridine, 4-propyl-pyridine, α-naphthylamine, 1-benzyl-naphthalene, 1- or 2-chloronaphthalene, any of the naphthalene diamines, naphthalene diols, dichloronaphthalenes, and dimethylnaphthalenes, 1-ethoxynaphthalene, 1- or 2-fluoronaphthalene, iopropylmethylnaphthalene, 1- or 2-ethylnaphthalene, 1-methylisopropylnaphthalene, 1-phenylnaphthalene, naphthamide and the like as well as any other compounds which come within the definition and formula set out hereinbefore which will occur to those skilled in the art.
Benzene and pyridine are also preferred aromatic compounds of the present invention when the production of aniline and 2-aminopyridine are the preferred objective. Aniline as well as toluene are likewise preferred aromatic compounds.
The aromatic amines prepared by the process of this invention are useful in any application in which prior art aromatic amines have been employed such as, for example, in the preparation of isocyanates used to react with polyols in the production of urethanes.
The invention is further illustrated but is not intended to be limited by the following examples in which all parts and percentages are by weight unless otherwise specified.
Preparation of Cataloreactant A
A. salt Precipitation
Cataloreactant A was prepared by stirring 150 parts of nickelous nitrate and 60 parts of zirconyl nitrate in 3 liters of deionized-distilled water until they dissolve. A solution of 60 parts of sodium hydroxide pellets in 6 liters of deionized-distilled water was added to the metal salt solution in one liter portions with stirring until all 6 liters had been added. The resulting gel was filtered, washed three times by mixing thoroughly with 40 liters of deionized-distilled water and finally filtered to yield a hard cake which was dried in an oven at 100° to 110° C. to yield hard, glassy granules.
B. conditioning
Approximately 250 parts of the hard glassy granules prepared in A were heated in an 18 × 11/4 inches Pyrex tube beginning at a temperature of 25° C. and increasing to 300° C over 1 hour at atmospheric pressure starting with a stream of 40 cc./min. of hydrogen and 360 cc./min. of nitrogen. As the temperature increased the percentage of H 2 in the stream was increased to 90 percent at 300° C. while the total gas flow was maintained at 400 cc./min. The temperature was then increased sharply to 380° C. while the flow of 90 percent H 2 and 10 percent N 2 gas was increased to 750 cc./min. These conditions were maintained for 5 hours after which the tube was cooled to 100° C. under 130 cc./min. N 2 and oxidized with 3 percent O 2 (130 cc./min. total flow) at 100° C. for 16 hours then 5 percent O 2 at 100° C. for 1 hour then 7 percent for 1 hour at 100° C. with the same total gas flow. About 150 parts of hard glassy conditioned cataloreactant granules were obtained.
Preparation of Cataloreactant B
A. salt Precipitation
Cataloreactant B was prepared in the same manner as cataloreactant A except that 3.0 parts of lanthanum nitrate were added simultaneously with the 150 parts of nickelous nitrate and 60 parts of zirconyl nitrate to 3 liters of deionized, distilled water.
B. conditioning
The conditioning of cataloreactant B was the same in every respect as the conditioning of cataloreactant A.
Cataloreactants C-L in Table I were prepared in the same manner except that the appropriate amount of nickel, zirconyl and dopant metal nitrate were used to yield the proportions set forth for the cataloreactants in Table I.
EXAMPLES 1-12
About 60 grams of cataloreactant were loaded into a 20 × 1/2 inches stainless steel reactor tube which was then attached to feed and exit lines. The reactor was heated to a reaction temperature of about 350° C. and ammonia and benzene at a mole ratio of NH 3 /C 6 H 6 of 3 were fed into the reactor at a rate of about 3.0 to 3.5 g./minute. The pressure in the reactor was maintained at 4400 to 4500 psig. Because the feed was premixed, only one pump was required, and the feed composition remained constant. Samples were collected every 10-15 minutes for a total of 120 minutes and analyzed by gas chromatography. The peak weight percent conversion of benzene to aniline over the total 120-minute period for cataloreactants A-L is set forth in the following table:
TABLE I______________________________________ Peak Weight PercentExample Conversion of Benzene -No. Cataloreactant to Aniline______________________________________1 A. Ni/0.3Zr 5.52 B. Ni/0.3Zr/.014La 9.43 C. Ni/.3Zr/.015Y 9.54 D. Ni/.3Zr/.015Ho 9.05 E. Ni/.3Zr/.015Dy 8.26 F. Ni/.3Zr/.015Yb 10.57 G. Ni/.3Zr/.015Sm 9.58 H. Ni/.3Zr/.015Pr 10.29 I. Ni/.2Zr/.014La 9.010 J. Ni/.3Zr/0.02Y 9.211 K. Ni/.2Zr/.028La 7.912 L. Ni/.3Zr/.042La 7.5______________________________________
EXAMPLES 13-17
A. preparation of Cataloreactant
The cataloreactant was prepared and conditioned as described in Example 2 except that 1.5 parts of lanthanum nitrate were added to the nickelous and zirconyl nitrates.
B. preparation of Aniline
241 gm. of the Ni/.3Zr/.007La cataloreactant of A were loaded into a 1 × 36 inches stainless steel reactor. The reactor was attached to feed and exit lines and heated to 350° C. The cataloreactant was purged with ammonia for 5 minutes after which the exit valve was closed and the reactor pressured to 125 to 140 psig with ammonia. After 10 more minutes the feed pump was started and ammonia and benzene at a molar ratio of 3 were introduced into the reactor at a rate of 7.8 to 8.5 grams of the mixture of ammonia and benzene. When the pressure reached 7000 psig the reaction was carried on for about 90 minutes. Samples were taken every 10 minutes during this 90 minute time period and analyzed by gas chromatography. At the end of the run the feed pump was stopped, and the reactor slowly vented to 500 psig.
In order to regenerate the cataloreactant, the reactor was flushed with nitrogen for 10 minutes at 500 psig after which a feed containing 1.3 percent oxygen in nitrogen was added to the reactor at about 0.5 to 1.0 standard cubic feet per minute until the uptake of oxygen ceased. The reactor was then purged with nitrogen and the next run started with the regenerated cataloreactant. The amount of aniline obtained in Example 13 for each 10 minutes of the 90-minute run is outlined in Table 2. A resume of runs 13 through 17 is outlined in Table 3.
TABLE 2______________________________________ Weight of Benzene Weight Percent and Aniline conversion ofSample No. Time recovered in Grams Benzene to Aniline______________________________________1 10 37.17 7.32 20 37.81 11.43 30 41.91 13.754 40 47.14 11.985 50 36.77 12.986 60 37.35 12.227 70 40.23 11.18 80 41.75 8.29 90 39.12 10.5______________________________________
TABLE 3______________________________________ Weight percent conversionExample of Benzene to Aniline______________________________________13 11.114 12.215 12.616 12.417 12.8______________________________________
It is to be understood that any of the components and conditions mentioned as suitable herein can be substituted for its counterpart in the foregoing examples and that although the invention has been described in considerable detail in the foregoing, such detail is solely for the purpose of illustration. Variations can be made in the invention by those skilled in the art without departing from the spirit and scope of the invention except as set forth in the claims. | An improved process is provided for producing an aromatic amine from ammonia and an aromatic compound which comprises reacting the aromatic compound with ammonia at a temperature of from about 150° C. to about 500° C. and at a pressure of from about 10 to about 1000 atmospheres in the presence of a conditioned nickel/nickel oxide/zirconium oxide cataloreactant containing an oxide of lanthanum, samarium, holmium, europium, erbium, yttrium, praseodymium, neodymium, terbium, ytterbium, dysprosium or a mixture of any of them. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to colloidal antimony pentoxide powders useful as flame retardants and which are dispersible to colloidal size in polar solvents.
Products of this nature are known in the art. For example, Nyacol Products, Inc., assignee of this invention manufactures and sells under the trade designation: ADP 494 a polar solvent-dispersible colloidal antimony pentoxide powder which may contain on the order of 71-75% by weight antimony pentoxide and in which the colloidal particles are hydrated pentoxide. In general, these agglomerates, which are on the order of 10-40 microns in diameter before dispersion, form dispersions in polar solvents of particles predominantly on the order of 0.03 micron.
The aforementioned colloidal antimony pentoxide powder may be prepared by admixing colloidal antimony pentoxide, phosphoric acid and a suitable ethoxylated fatty acid amine; and thereafter drying in air to an adsorbed moisture content of no greater than three percent.
While the foregoing commercially available product has enjoyed commercial success and is entirely satisfactory for most contemplated uses, it nevertheless possesses less than optimum dispersibility in polar solvents.
Stated simply, the task of this invention is to provide colloidal antimony pentoxide powders of the foregoing general description and which have improved dispersibility in polar solvents.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the present invention, this task is solved in a simple and elegant manner by the steps of: (1) forming a sol consisting of antimony pentoxide sol and phosphoric acid; (2) concentrating the sol until the concentration by weight of antimony pentoxide is at least 35 percent, and preferably 50 percent or greater without gelation; (3) adding this concentrated phosphated sol to ethoxylated fatty acid amine; and (4) drying the resulting mixture to provide a colloidal antimony pentoxide powder having an adsorbed moisture content of no greater than 3.0 percent.
DETAILED DESCRIPTION OF THE INVENTION
As heretofore mentioned, it is known to prepare colloidal antimony pentoxide powders dispersible in polar solvents by admixing colloidal antimony pentoxide, phosphoric acid and a suitable ethoxylated fatty acid amine and then drying to an adsorbed moisture content of no greater than three percent. Specifically, a product of this description is commercially available from Nyacol Products, Inc. under the trade designation ADP 494.
While entirely satisfactory for most contemplated usages, the dispersibility of the powder in the polar solvent is less than optimum. Specifically, there is a tendency for "clumping" or flocculation to occur. Moreover, colloidal antimony pentoxide powders formed in the foregoing manner tend to vary greatly in the percentage of sol dispersed in the polar solvent which will pass through a nominal (e.g. paper) 8 micron filter. Specifically, this percentage has been found to range from 0.5 to as much as 20 percent which will not pass.
The present invention provides a preparation which will permit at least 99.9 percent to pass through the 8 micron filter or, stated another way, in which 0.1 percent or less will not pass. This not only appreciably enhances dispersibility in a polar solvent, but also provides a product which is extremely uniform and predictable from a quality control standpoint in terms of the particle size of the dispersion.
The concentrated phosphated sol consisting solely of antimony pentoxide and phosphoric acid wherein the percentage by weight of antimony pentoxide is at least 35 percent is believed by Applicants to be novel in that they are not aware of any known sols of this description having an antimony pentoxide percentage this high without the addition of amine or some other additive. This novel intermediate is capable of independent usage in products which preclude the presence of the amine and/or other organic material.
The presence of both the phosphoric acid and the amine in the colloidal powders to which this invention is directed is necessary to provide dispersibility in the polar solvent. Although the percentages of each are not capable of precise quantification, the selection of particular percentages to be employed will at most require minimal routine experimentation and in any case will be within the expected judgement of the skilled worker in the light of this description. Accordingly, in the appended claims the amounts so used may be defined as being "effective amounts", meaning amounts sufficient to provide the desired effective dispersibility in the selected polar solvent. By way of illustration, amounts of phosphoric acid as low as 2.2 percent of the weight of antimony pentoxide and of amine as low as 4.0 percent have been found to be acceptable.
The amines employed in the practice of this invention may in general be described as being ethoxylated amines derived from higher fatty acids containing at least 12 carbon atoms, e.g. tallowamine, cocoamine, oleylamine, soyaamine, etc. Preferred are the class of tertiary amines having one to two fatty alkyl groups (derived from various fatty sources having 12-18 carbon atoms) and one to two polyoxyethylene groups attached to the nitrogen atom.
Suitable polar solvents to be employed include acetone, acetonitrile, dimethylacetamide, methylethylketone, etc.
The colloidal antimony pentoxide powders of this invention may be employed to provide flame retardancy in the manner heretofore known in the art, e.g. coating or impregnating textiles or other articles to be treated with a dispersion comprising the powder in a polar solvent as heretofore described, and then drying to remove the solvent.
The following examples show by way of illustration and not by way of limitation the practice of this invention.
EXAMPLE 1
1822.6 gms. of antimony pentoxide sol were treated with 8.29 gms. of phosphoric acid (85%). [This is equivalent to about 2.2 percent phosphoric acid of antimony pentoxide.] The resulting sol was concentrated by boiling to provide a phosphated sol containing about 53.83 percent antimony pentoxide and having a specific gravity of 1.933. [It is notable that the dried solids which tend to cake on the beaker wall at the surface were very easily redispersed upon rinsing with water.]
EXAMPLE 2
7.33 gms. of 85 percent phosphoric acid were added to 1510.88 grams of antimony pentoxide sol containing 288 grams of antimony pentoxide. 380.05 grams of this sol were then heated to remove water to provide a concentrated phosphated sol containing about 56.6 percent antimony pentoxide and having a specific gravity of 2.031
EXAMPLE 3
33.44 gms. of the phosphated concentrated sol prepared in Example 1 were added to 7.2 gms of 30 percent "ETHOMEEN" C/25 (trademark of Akzo Chemical for a polyoxyethylene (15) cocoamine. The resulting mixture was dried for about 3 hours at 107° C. on a flat plate to a moisture content of about 0.5 percent. After drying the dried cake was ground in a mortar. The colloidal antimony pentoxide powder so obtained was dissolved in dimethyl acetamide polar solvent with mild mixing. 100 percent (all) of the dispersion passed through a nominal 8 micron filter.
EXAMPLE 4
Example 3 was repeated using 6.0 gms. of 30% "ETHOMEEN" C/25 instead of 7.2 gms. Again 100% passed through the 8 micron filter.
From the foregoing illustrative examples, it will thus be seen that the present invention provides an elegant and highly efficacious procedure for obtaining greatly improved dispersibility in a polar solvent and moreover greatly improves quality control where the dispersed particles should be in a narrower size range, e.g. where at least 99.9 percent will pass through an 8 micron filter.
Since certain changes may be made without departing from the scope of the invention herein contemplated, it is to be understood that the foregoing description, including the examples, is to be taken as illustrative and not in a limiting sense. | Disclosed are a novel class of colloidal antimony pentoxide powders having improved dispersibility in polar solvents; and novel processes for preparing same, which processes include the initial step of preparing a new intermediate consisting of an antimony pentoxide/phosphoric acid sol containing at least 35% by weight of antimony pentoxide based upon the total weight of the sol. | 2 |
The present invention relates to machines for inserting an insulation displacement contact into a connector housing, concurrently terminating the conductor of an electrical component to the contact, and trimming the length of a wire terminated to the conductor.
BACKGROUND OF THE INVENTION
Machines that automatically sever an insulation displacement contact from a carrier strip, insert the contact into an insulating connector housing, terminate a wire to the contact, and trim the end of the wire flush with the edge of the housing, are necessarily complex and require that certain of the operational steps be performed after other steps are completed. In particular, the trimming to length of the wire is done after it is terminated to the contact so that the wire is firmly held in place by the contact during trimming. This requires two separate operations that occur sequentially, that is, after the contact is inserted into the housing a cutting blade is actuated to sever the terminated wire. It is desirable to overlap some of these operational steps, such as the insertion step and the wire trimming step, to reduce the overall cycle time of the machine. However, such overlapping is dependent, in part, on timing and the length of the insertion stroke. Overlapping is especially difficult to achieve in cases where the parts are extremely small resulting in the need for a relatively short insertion stroke. In these cases lost motion mechanisms and other similar devices are used to accomplish the operations, however, without the desired overlapping. However, these devices increase the complexity of the machine and its cost to manufacture and to maintain. Other means for performing the insertion and trimming functions is by utilizing separate actuators. This solution, of course, also increases the complexity and cost of the machine. What is needed is a machine, for terminating very small contacts to wires, that overlaps the insertion function with the wire trimming function so that the two functions are done concurrently during the insertion stroke with a single actuator.
SUMMARY OF THE INVENTION
A machine and method are disclosed for severing an insulation displacement contact from a carrier strip and inserting the contact into a connector housing while concurrently terminating a wire of an electrical component to the contact. The machine includes a frame and an inserter coupled to the frame. The inserter is arranged to hold and move the contact in a first direction into inserted engagement with the housing and into terminated engagement with the wire. A trimming mechanism is provided and is operable by the inserter for severing the wire to length during the moving of the contact in the first direction.
DESCRIPTION OF THE FIGURES
FIG. 1 is a plan view of a machine incorporating the teachings of the present invention;
FIG. 2 is a combination of left side and cross-sectional view of the machine taken along the lines 2--2 of FIG. 1;
FIG. 3 is a front view of the machine shown in FIG. 1;
FIG. 4 is a partial cross-sectional view of the machine taken along the lines 4-4 in FIG. 1;
FIG. 5 is an enlarged partial view of the area indicated as 5-5 in FIG. 2;
FIG. 6 is an enlarged view of a portion of the clamping mechanism of the machine shown in FIG. 2;
FIG. 7 is a side view of the mechanism shown in FIG. 6;
FIG. 8 is a cross-sectional view of the wire trimming and housing cutting mechanism taken along the lines 8--8 of FIG. 2;
FIG. 9 is an exploded parts view of the wire trimming and housing cutting mechanism shown in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
There is shown in FIG. 1, 2, 3, and 4 a machine 10 having a frame 12 consisting of a base plate 14 and a locating bar 16 rigidly attached to the base plate by means of the screws 18. A controller 20 is mounted to one end of the base plate 14 and includes electrical circuitry for controlling the various operating functions of the machine 10. While the controller 20 will not be described further here, the various functions that it controls will be described in detail. The four basic functional element of the machine 10 include a contact feed unit 22, a connector housing feed unit 24, a wire trim and housing cutoff unit 26, and contact cutoff and inserter unit 28. The connector housing feed unit 24 is attached to the wire trim and housing cutoff unit 26, which, along with the contact feed unit 22 and the contact cutoff and insertion unit 28, are attached to the locating bar 16, thereby forming an assembly that can be removed from the base plate for maintenance or other purposes as desired.
As shown in FIGS. 1, 2, 6, and 7, the contact cutoff and insertion unit 28 includes a horizontally disposed slide attached to the locating bar 16 by means of screws 32 which are threaded into holes in the bar 16. The slide 30 includes a movable portion 34 that is arranged to move in a first direction, indicated by the arrow A in FIG. 6, and in an opposite direction. Movement of the movable portion 34 is effected by means of an air cylinder 35 that is attached to the frame and has a piston rod 37 that is coupled to the movable portion 34 by means of a clevis and pin 39 in the usual manner. A vertically disposed slide member 38 is arranged to slide within ways formed by gibs 36 that are attached to the movable portion 34 by means of screws 33. The slide member 38 is arranged to move in a direction, indicated by the arrow B in FIG. 6, and in an opposite direction, perpendicular to the first direction, indicated by the arrow A. Therefore, the two slides 30 and 38 provide for orthogonal motion of the member 38 both parallel and perpendicular to the base plate 14. The movable slide 38 includes an extended shank 40 having a recess 42 and adjacent shoulder 44. A fixed clamping member 46 is rigidly attached within the recess 42 and against the shoulder 44 by means of two screws 48. As best seen in FIGS. 6 and 7, the fixed clamping member 46 has another recess 50 at one end thereof containing an upper jaw 52 that is attached thereto by means of two screws 54. The other end of the fixed clamping member 46 has an extended arm 56 to which an air cylinder 58 is anchored by means of a clevis 60 and pin 62. A movable clamping member 64 is pivotally attached to the shank 40 by means of a pin 66. A recess 68 is formed in the end of the clamping member 64 and includes a lower jaw 70 which is secured within the recess by means of two screws 72 which are threaded into holes in the clamping member. As can be seen in FIG. 7, the movable clamping member 64 is offset from the fixed clamping member 46 by an amount that is approximately the same as the thickness of each of the clamping members. However, the lower jaw 70 is offset an equal amount so that it is in clamping alignment with the upper jaw 52. The air cylinder 58 includes a piston rod 74 that is pivotally attached to an arm 76 by means of a clevis 77 and pin 78. The two clamping members 46 and 64 are arranged so that when the air cylinder 58 is actuated the movable clamping member 64 is pivoted about the pivot 66 and the lower jaw 70 engages and clamps two contacts 80 against the upper jaw 52. A shearing plate 82 having a sharp shearing edge 84 is rigidly attached to the top 86 of the movable portion 34 of the slide 30, as shown in FIGS. 5, 6 and 7. The upper jaw 52 includes a sharp shearing edge 88 that is in shearing alignment with the edge 84 of the shearing plate 82. When the slide 38 is moved in the direction of the arrow B, the contacts 80, which are securely clamped between the two jaws, is severed from the carrier strip 90 and moved downwardly a precise amount for a purpose that will be explained. The movement of the slide 38 is effected by means of an air cylinder 92, as best seen in FIG. 4, that is attached to the slide 38 by means of four screws 96, as shown in FIG. 2. The air cylinder 92 has a piston rod 98 that is pivotally attached to a clevis 100 by a pin 102, the clevis being attached to the movable portion 34 by two screws 104. The carrier strip 90 and attached contacts 80 are fed along a track 106, as best seen in FIGS. 1 and 3, by a feed mechanism 108 in the usual manner.
As shown in FIGS. 8 and 9, the wire trim and housing cutoff unit 26 includes a two part body consisting of a vertical block 110 and a side block 112 attached thereto by means of two screws 114 that are threaded into holes 116 in the vertical block 110. The vertical block 110 is located in a recess 118 formed in the locating bar 16 and secured in place by means of two screws 120 threaded into holes in the bottom of the vertical block 110, as best seen in FIG. 8. The side block 112 has a recessed surface 122 facing upwardly, as viewed in FIGS. 8 and 9, and an adjacent shoulder 124. A first slide bar 126 is in sliding engagement with the surface 122 and shoulder 124. The vertical block 110 includes a recess 128 and adjacent shoulder 130, which along with the side 134 of the side block 112 and the edge of the first slide bar 126 form a channel. A second slide bar 132 is disposed within the channel in sliding engagement with the surface 128 and the shoulder 130, as viewed in FIG. 8. A cover plate 136 is disposed on the top surfaces 138 and 140 of the side block 112 and the vertical block 110, respectively, and is held in place by a saddle 142 and four screws 144 that are threaded into holes 146 in the side and vertical blocks. The cover plate 136 confines the first and second slide bars 126 and 132 is sliding engagement with their respective recesses 122 and 128. As best seen in FIG. 9, the side block 112 includes an undercut 148 at one end thereof and a flange 150 extending outwardly from the floor of the undercut near one side. A lever 152 has a rectangular portion 154 that is received within the undercut 148 between the flange 150 and the wall 156 of the undercut. The lever 152 includes an offset portion 158 spaced from the rectangular portion so that the flange 150 is disposed therebetween, as shown in FIGS. 3 and 9. The lever 152 is pivotally attached to the side block 112 by means of a pin 160 extending through a hole 162 that extends through both the wall 156 and the flange 150 and a hole 164 that extend through the rectangular portion 154.
The lever 152 includes a first end 166 that is arranged to abut a second end 168 of the first slide bar 126 when the slide bar is urged in the first direction indicated by the arrow C in FIG. 9. An elongated opening 170 is disposed in the surface of the recess 122, which contains a spring 172. A pin 174 extends downwardly from the first slide bar 126 and into the elongated opening 170 so that the spring 172 urges the pin and first slide toward the lever 152. A screw 176 having an abutting surface 178 is threaded into a hole in the offset portion 158 so that the screw 176 is in alignment with a second end 180 of the second slide bar 132. An elongated opening 182 is disposed in the surface of the recess 128, which contains a spring 184. A pin 186 extends outwardly from the second slide 132 and into the elongated opening 182 so that the spring urges the pin and second slide in a second direction opposite the first direction, as indicated by the arrow D in FIG. 9. As shown in FIG. 9, the first end 166 of the lever 152 is vertically above the pivot pin 160 while the abutting surface 178 of the screw 176 is vertically below the pivot pin. Therefore, as the second slide 132 is moved in the first direction, indicated by the arrow C, the second end 180 pushes against the abutting surface 178 of the screw 176 thereby causing the lever 152 to pivot about the pin 160 so that the first end 166 pushes against the second end 168 of the first slide bar 126, causing the first slide bar to move in the second direction, indicated by the arrow D. The ratio of movement of the first slide bar to the second slide bar is controlled by the ratio of distances of the first end 166 from the pivot pin 160 and the abutting surface 178 from the pivot pin 160, respectively. This ratio, in the present example is about 2 to 1 so that 0.018 inch movement of the second slide bar 132 in the first direction will cause about 0.036 inch movement in the first slide bar in the second direction. This ability of the first slide bar to undergo greater movement than the second slide bar is important to the operation of the present invention, as will be explained below. A set screw 188 is threaded into a hole in the vertical block 110 so that it intersects the end of the elongated opening 182, and serves as an adjustable stop for limiting movement of the second slide bar 132 in the second direction. Similarly, a screw 190 is threaded into a hole in the lever 152 and arranged to engage the floor of the recess 148 to limit movement of the first slide bar 126 in the first direction. A wire cutting blade 192 having a wire severing edge 193 is attached to a first end of the first slide bar 126 by means of two screws 195 that are threaded into holes in the slide bar. Additionally, a housing cutoff blade 194 having a severing edge 196 is attached to a first end of the second slide bar 132 by one screw 198 that are threaded into holes in the slide bar.
As shown in FIGS. 5 and 9, a shear plate 200 having a top surface 202 is attached to the surface 140 of the vertical block 110 by means of two screws 204 that are threaded into holes 206 in the block 110. The severing edge 196 extends up to and flush with the top surface 202 and in shearing alignment with two shearing edges 208 in the plate 200. Insulated housings 210 that are to receive the contacts 80 are in strip form and shown in phantom lines in FIG. 9, and are interconnected by short segments that must be removed during insertion of the contact. This is accomplished by the severing edges 196 in cooperation with the shearing edges 208 when the second slide bar 132 is moved in the first direction, as indicated by the arrow C in FIG. 9. As best seen in FIG. 5, a bracket 212 is attached to a plate 262 with the screws 214. The plate 262 is attached to the side of the vertical block 110 by means of an angled bracket 264 and suitable screws. The bracket 212 supports a rail 216 and flat spring member 218 that are secured to the bracket by means of screws 220 which are threaded into holes in the bracket. The spring member 218, rail 216, plate 262, and the edge of the shear plate 200 cooperate to form a channel for guiding the strip of housings 210, the spring member serving to urge the housings against the edge of the shear plate. The strip of housings is fed by a feed mechanism 222, shown in FIG. 3, of conventional design. A stop surface 224 extends from the end of the cover plate 136 and limits movement of the strip of housings 210 along the feed path and accurately positions each housing to be cut off by the severing edge 196.
As shown in FIG. 2, an electrical component 240 having a pair of wires 242 to be terminated contacts 80 in a housing 210 is positioned in a nest 244 with the wires extending downwardly through guide slots in a first guide plate 246 and through openings in the insulated housing 210. The first guide plate 246 is arranged to slide within a groove 248 formed in the saddle 142, between a fully forward position shown in FIG. 1 to a retracted position that permits removal of the terminated assembly. The first guide plate 246 is spring biased in its forward position and is manually retracted by means of the knob 250. A second guide plate 252 having an L-shaped end 254 is arranged to slide within the groove 248 adjacent the first guide plate 246 so that the end 254 is in front of and closes the ends of the guide slots in the first guide plate 246. This second guide plate 252 is spring biased in an opposite direction to the first guide plate so that the L-shaped end 254 remains in this position against the end of the first guide plate 246. It may be manually moved away from the guide slots in the first guide plate by pushing the knob 256 forward toward the saddle 142, as viewed in FIG. 1. Therefore, after terminating a component's wires to a housing, the assembly may be removed from the machine by simply pushing the two knobs 250 and 256 in opposite directions.
In operation, a strip of contacts 80 is loaded into the contact feed unit 22 and a strip of housings 210 is loaded into the housing feed unit 24. An electrical component 240 is positioned in the nest 244 with its wire leads 242 extending through the guide slots in the guide plate 246 and through the housing 210. The machine 10 is then cycled to begin operation. The cylinder 58 is actuated to pivot the movable clamping member 64 from its position shown in FIG. 6 to its closed position shown in FIG. 5 where two contacts 80 are securely clamped between the two jaws 52 and 70. The cylinder 92 is then actuated causing the slide 38 to move downwardly in the direction indicated by the arrow B in FIG. 6. This causes the shearing edge 88 of the upper jaw 52 in cooperation with the shearing edge 84 to sever the two contacts 80 from the carrier strip 90. As downward movement continues, the two severed contacts 80 are brought into alignment with the insulated housing 210 as shown in phantom lines at 258 in FIG. 5. The cylinder 35 is then actuated causing the movable portion 34 of the slide 30 to move in the first direction as indicated by the arrow A in FIG. 6. As the insulation displacement contacts 80 enter the housing 210 they begin to engage the wires 242. Concurrently, an abutting screw head 260, as best seen in FIGS. 2, 4, 6 and 7, projecting from the movable portion 34 engages the end of the second slide bar 132 adjacent the cutoff blade 194, pushing the slide bar in the first direction, as indicated by the arrow C in FIG. 9. The second end of the second slide bar engages the abutting surface 178, shown in FIG. 9, causing the lever 152 to pivot so that its end 166 engages the second end 168 of the first slide bar 126 causing it to move in the second direction, as indicated by the arrow D in FIG. 9. At this point there is sufficient interference between the contacts 80 and the wires 242 so that the wires are firmly held in place, although the movable portion 34 still must move an additional amount of about 0.015 inch to fully seat the contacts 80 for proper termination of the wires to the contacts. During this additional movement the cutting edge 193 of the wire cutoff blade 192 engages the wires 242 extending below the housing 210 and severs them flush with the housing. At this point the contacts 80 are fully inserted into the housing and terminated to the wires 242. The cylinder 58 is then reversed to open the jaw 70 and the movable portion 34 of the slide 30 is withdrawn to its position shown in FIG. 2 by reversing the cylinder 35. The slide 38 is returned to its original position, shown in FIG. 6, by reversing the cylinder 92. The two knobs 250 and 256 are manually manipulated as described above, the completed assembly is removed. Additional contacts 80 and a housing 210 are fed into position for the next cycle by the feed mechanisms 108 and 222, respectively, and the process repeated as desired. While, in the present example, wires of an electrical component were terminated to the contacts 80 in the housing 210, individual wires without components attached may also be terminated in this manner.
An important advantage of the present invention is that the wire trimming function is performed concurrently with the contact insertion function thereby reducing machine cycle time. This is done while assuring that the wires being trimmed are held securely in place during the operation thereby improving reliability of the product. Additionally, the two functions are accomplished by means of a single actuator, thereby reducing complexity and costs. | The present invention is an improved machine (10) that automatically severs an insulation displacement contact (80) from a carrier strip (90), inserts the contact into an insulating connector housing (210), terminates a wire (242) to the contact (80), and trims the end of the wire flush with the edge of the housing (210). The trimming operation is accomplished during the last part of the contact insertion stroke, after the insulation displacement contact (80) has just begun to engage the wire (242), so that the wire is securely held in place during trimming. A pair of opposite moving slide (126, 132) are utilized where one slide (132) is moved directly by the inserter (28, 260) so that it causes a lever (152) to pivot which in turn moves the other slide (126), carrying the wire trimming blade (192), in the other direction. The lever (152) is arranged so that movement of the one slide (132) results in a greater movement of the other slide (126). Therefore, the movement of the last part of the contact insertion stroke results in a larger movement of the wire trimming blade (192). | 8 |
TECHNICAL FIELD
The present invention relates to polymethylpentene conjugate fiber and porous polymethylpentene fiber. More specifically, the invention relates to polymethylpentene conjugate fiber in which the lightweight polymethylpentene fiber has deep, vivid colors. It also relates to porous polymethylpentene fiber that is very light in weight, highly uniform in pore size, and high in pore resistance to external force. Polymethylpentene conjugate fiber and porous polymethylpentene fiber that can be obtained according to the present invention can be adopted favorably as fiber structures such as woven and knitted fabrics, nonwoven fabrics, spun yarns, and wadding.
BACKGROUND ART
Polyethylene fiber and polypropylene fiber, which fall under the category of polyolefin fiber, are light in weight and high in chemical resistance, but have the disadvantage of low heat resistance due to low melting points and also have the disadvantage of being difficult to dye due to the absence of polar functional groups. These defects make them unsuitable as clothing material and accordingly they are currently used in a limited range of applications including interior materials such as tile carpets, household carpets, and automobile mats, and general materials such as ropes, protective nets, filter fabrics, narrow tapes, braids, and chair upholstery.
Polymethylpentene is also a polyolefin based polymer, but different from polyethylene or polypropylene in that polymethylpentene is low in specific gravity and very light in weight as compared to polyethylene and polypropylene. Furthermore, being higher in heat resistance than other polyolefins due to a higher melting point and softening point, it can be ironed and is expected to serve as material intended for use at high temperatures. However, it is difficult to dye like other polyolefin based fibers, still leaving problems in applying to clothing applications.
Adding a pigment is a simple dyeing method for polyolefin based fibers. The use of a pigment, however, cannot serve effectively to develop vivid colors as compared to the use of a dye, and there is the disadvantage that pigments tend to stiffen fibers, leading to products with low softness.
As a dyeing method to replace the use of pigments, there is a proposal of surface modification of polyolefin based fibers. For example, Patent document 1 describes an attempt at improving dyeing properties through surface modification of polyolefin based fibers by performing ozone treatment or ultraviolet ray irradiation to cause graft copolymerization of vinyl compounds.
In addition, there are proposals of techniques that combine a polyolefin with poor dyeing properties with dyeable resin to form a composite material. Patent document 2 and Patent document 3, for example, propose core-sheath type conjugate fibers composed mainly of polymethylpentene as sheath component and polyester or polyamide as core component.
General methods relating to the lightening of fibers, on the other hand, include the formation of hollow parts and pores. Hollow parts and pores contain air and therefore serve to develop good functions such as heat insulation and cushioning properties as well as lightness. Hollow yarns can be produced easily by melt spinning but have the disadvantage that hollow parts can be deformed or destroyed during processing steps such as false-twisting and twining.
Various proposals have been made to provide methods for forming pores in fiber. In Patent document 4, for example, polyolefin fiber is heat-treated and then stretched to form pores. In this proposal, polyolefin is crystallized by heat treatment, and crystalline parts and amorphous parts are separated at their boundaries by stretching to form pores.
In Patent document 5, a polyolefin composition composed of polyolefin and fine particles is processed into fiber, which is then stretched to form pores. In this proposal, pores are formed by stretching to separate polyolefin and fine particles at their boundaries.
In Patent document 6, a polyolefin composition composed of polyolefin and paraffin wax is subjected to a fiber production process to produce a sea-island fiber, and then the paraffin wax, i.e. island component, is dissolved out with a solvent to form pores.
PRIOR ART DOCUMENTS
Patent Documents
Patent document 1: Japanese Unexamined Patent Publication (Kokai) No. HEI 7-90783
Patent document 2: Japanese Unexamined Patent Publication (Kokai) No. HEI 9-87927
Patent document 3: Japanese Unexamined Patent Publication (Kokai) No. HEI 9-157960
Patent document 4: Japanese Unexamined Patent Publication (Kokai) No. HEI 6-246140
Patent document 5: Japanese Unexamined Patent Publication (Kokai) No. HEI 10-259519
Patent document 6: Japanese Unexamined Patent Publication (Kokai) No. HEI 4-18112
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
The method to develop colors in polyolefin based fibers described in Patent document 1, however, requires a long processing time for ozone treatment and ultraviolet ray irradiation, leading to low productivity and difficulties in industrialization.
The methods proposed in Patent documents 2 and 3, furthermore, can form core-sheath type conjugate fibers containing dyeable resin as core component so that colors can be developed in the fibers, but such colors are not sufficiently vivid or deep.
The first object of the present invention is to solve the above-mentioned problems with the conventional techniques and produce lightweight polymethylpentene fiber with deep, vivid color developing property to provide polymethylpentene conjugate fiber that can be adopted favorably as fiber structures such as woven and knitted fabrics, nonwoven fabrics, spun yarns, and wadding.
The methods relating to the lightening of fibers described in Patent document 4, on the other hand, have the disadvantages that the fiber is easily broken as it is stretched and that the pore size is different between the outer layers and inner layers in the stretched fiber, leading to difficulty in controlling the pore size.
The method described in Patent document 5 has the disadvantages that thread breakage takes place easily during melt spinning due to coagulation of fine particles and that pore size variations occur easily during stretching in addition to thread breakage. Furthermore, there is also the disadvantage that the porous fiber produced by the stretching contains residual fine particles.
In the case of the method proposed in Patent document 6, furthermore, since paraffin wax commonly has a melting point of 50 to 70° C., paraffin wax will have an excessively high flowability at a spinning temperature suitable for polymethylpentene when composite material is produced through its melt spinning with polyolefin having a high melting point, such as polymethylpentene, making it difficult to control the dispersion diameter of the paraffin wax, i.e., island component. As a result, porous fiber produced by dissolving out the island component is not sufficiently uniform in pore size and the pores are easily deformed when an external force is applied.
The second object of the present invention is to solve the above-mentioned problems with the conventional techniques and produce porous polymethylpentene fiber that is very light in weight, highly uniform in pore size, and high in pore resistance to external force and accordingly can be adopted favorably as fiber structures such as woven and knitted fabrics, nonwoven fabrics, spun yarns, and wadding.
Means of Solving the Problems
The first object of the present invention can be met by polymethylpentene conjugate fiber having a sea-island structure that includes polymethylpentene based resin as sea component and thermoplastic resin as island component.
The thermoplastic resin is preferably formed of one or more compounds selected from the group consisting of polyester, polyamide, thermoplastic polyacrylonitrile, thermoplastic polyurethane, and cellulose derivatives.
For the fiber to be adopted favorably, furthermore, it is preferable that the coefficient of variation CV of the dispersion diameter of the island domains in the fiber cross section is in the range of 1 to 50%, that the content ratio (by weight) of the sea component to the island component is in the range of 20/80 to 99/1, that the dispersion diameter of the island domains in the fiber cross section is in the range of 0.001 to 2 μm, and that the specific gravity of the fiber in the range of 0.83 to 1.1.
The second object of the present invention can be met by a porous polymethylpentene fiber formed of polymethylpentene based resin in which the coefficient of variation CV of the diameter of the pores in the fiber cross section is 1 to 50%.
It is preferable that the average diameter of the pores in the fiber cross section is 0.001 to 2 μm, that the porosity of the fiber is 0.1 to 70%, and that the specific gravity of the fiber is 0.25 to 0.80. The second object of the present invention can be met favorably by adopting a porous polymethylpentene fiber production method in which polymethylpentene conjugate fiber having a sea-island structure including polymethylpentene based resin as sea component and thermoplastic resin as island component is produced, followed by dissolving out at least part of the island component.
The method can be adopted favorably to produce a fiber structure formed at least partly of the polymethylpentene conjugate fiber or the porous polymethylpentene fiber.
Advantageous Effect of the Invention
The present invention serves to provide polymethylpentene conjugate fiber that is formed of very lightweight polymethylpentene fiber and at the same time able to have deep, vivid colors. The present invention also serves to provide porous polymethylpentene fiber that is very light in weight, highly uniform in pore size, and high in pore resistance to external force. If processed into a fiber structure such as woven and knitted fabrics, nonwoven fabrics, spun yarns, and wadding, the polymethylpentene conjugate fiber and porous polymethylpentene fiber produced according to the present invention can be used favorably as clothing material and in a wide range of applications that require lightness and color developing property in addition to interior and general material applications where conventional polyolefin based fibers have been used.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a photograph that is given as an alternative to a diagram to show a fiber cross section of porous polymethylpentene fiber according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
The polymethylpentene conjugate fiber according to the present invention has a sea-island structure containing polymethylpentene based resin as sea component and thermoplastic resin as island component. The polymethylpentene based resin of the sea component is a resin that is high in transparency and low in refractive index and accordingly, good colors can be developed in the inner parts of the fiber by dyeing the thermoplastic resin of the island component, making it possible to form polymethylpentene conjugate fiber that contains polymethylpentene based resin and has color developing property. Furthermore, unlike the conventionally proposed core-sheath type structure that is composed of polymethylpentene as sheath component and dyeable resin as core component, the sea-island structure according to the present invention contains a plurality of, preferably a large number of, dyed island domains arranged in a sea domain so that transmitted beams through the island domains and reflected beams from the island domains are mixed randomly to give deep, vivid colors. In addition, unlike the core-sheath type structure, the island domains of dyeable resin are scattered over the fiber cross section to achieve higher color developing property as compared to the core-sheath type structure with the same content ratio. The sea-island structure according to the present invention may be a sea-island structure produced by multi-component fiber spinning in which island domains are located continuously in the fiber length direction, and in this case the number of island domains in the polymethylpentene conjugate fiber is preferably eight or more. Alternatively, this sea-island structure may be a sea-island structure that is produced through polymer alloy type spinning of a resin to form the sea and a resin to form islands and in which the island domains have finite lengths in the fiber length direction.
The porous polymethylpentene fiber according to the present invention is formed of polymethylpentene based resin and the coefficient of variation CV of the pore diameter in the fiber cross section is in the range of 1 to 50%. By making the polymethylpentene fiber porous, the polymethylpentene based resin, which originally has a low specific gravity, can be made still lighter and furthermore, can obtain a good heat insulation function and cushioning function. Furthermore, if the coefficient of variation CV of the pore diameter in the fiber cross section is in the range of 1 to 50%, it is possible to obtain porous polymethylpentene fiber with high uniformity in pore size. Accordingly, it becomes possible to depress the pore deformation and collapse and fiber rupture due to stress concentrations, leading to the formation of porous polymethylpentene fiber with a high pore resistance to external force as well as high durability.
Useful polymethylpentene based resin for the present invention include 4-methyl-1-pentene based polymers, which may be either a homopolymer of 4-methyl-1-pentene or a copolymer of 4-methyl-1-pentene with other α-olefins. Such a copolymer may contain only one or a plurality of these other α-olefins (hereinafter occasionally referred to simply as α-olefins).
These α-olefins preferably contain 2 to 20 carbon atoms and the molecular chains of the α-olefins may be either straight chains or branched chains. Specific examples of these α-olefins include, but not limited to, ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicosene, 3-methyl-1-butene, 3-methyl-1-pentene, 3-ethyl-1-pentene, and 3-ethyl-1-hexene.
In a polymethylpentene based resin to be used for the present invention, the copolymerization ratio of α-olefins is preferably 20 mol % or less. A copolymerization ratio of α-olefins of 20 mol % or less is preferable because in that case, it is possible to obtain polymethylpentene conjugate fiber and porous polymethylpentene fiber that have good mechanical characteristics and high heat resistance. The copolymerization ratio of α-olefins is more preferably 15 mol % or less and still more preferably 10 mol % or less.
Polymethylpentene based resin used for the present invention preferably has a melting point of 200 to 250° C. Polymethylpentene based resin with a melting point of 200° C. or more is preferable because in that case, the resulting polymethylpentene conjugate fiber and porous polymethylpentene fiber will have high heat resistance. On the other hand, the use of polymethylpentene based resin with a melting point of 250° C. or less is preferable because in that case, high spinning operability will be ensured when conjugate fiber is produced through melt spinning with thermoplastic resin. The polymethylpentene based resin more preferably has a melting point of 210 to 245° C., still more preferably 220 to 240° C.
Polymethylpentene based resin used for the present invention preferably has a melt flow rate (MFR) of 5 to 200 g/10 min as measured under the conditions of a temperature of 260° C. and a load of 5.0 kg according to ASTM D1238. The use of polymethylpentene based resin with a melt flow rate 5 g/10 min or more is preferable because in that case, increased high-temperature flowability and high molding processability are ensured. On the other hand, the use of polymethylpentene based resin with a melt flow rate of 200 g/10 min or less is preferable because in that case, polymethylpentene conjugate fiber and porous polymethylpentene fiber with good mechanical characteristics are obtained. The polymethylpentene based resin more preferably has a melt flow rate of 10 to 190 g/10 min, still more preferably 20 to 180 g/10 min.
Polymethylpentene based resin used for the present invention may be one that has been modified through various methods by adding minor additives. Specific examples of such minor additives include, but not limited to, compatibilizer, plasticizer, ultraviolet absorber, infrared ray absorbent, fluorescent brightening agent, mold releasing agent, antibacterial agent, nuclear formation agent, thermal stabilizer, antioxidant, antistatic agent, color protection agent, adjustor, delustering agent, antifoam agent, antiseptic agent, gelatinizer, latex, filler, ink, coloring agent, dye, pigments, and perfume. These minor additives may be used singly, or a plurality thereof may be used in combination.
There are no specific limitations on the thermoplastic resin to be used to produce the polymethylpentene conjugate fiber according to the present invention and it can be adopted favorably as long as it can be melt-spun in combination with polymethylpentene based resin to form conjugate fiber having a sea-island structure and can be dyed with a dye. Specific examples of such thermoplastic resin to be used for the polymethylpentene conjugate fiber according to the present invention include, but not limited to, polyester, polyamide, thermoplastic polyacrylonitrile, thermoplastic polyurethane, modified polyolefin, polyvinyl chloride, and cellulose derivatives. Polyester, polyamide, thermoplastic polyacrylonitrile, thermoplastic polyurethane, and cellulose derivatives are preferable because of good color developing properties, of which polyester and polyamide can be adopted favorably because of good mechanical characteristics.
There are no specific limitations for the favorable adoption of the thermoplastic resin to be used to produce the porous polymethylpentene fiber according to the present invention as long as it can be melt-spun in combination with polymethylpentene based resin to form conjugate fiber having a sea-island structure and the thermoplastic resin of the island component can be dissolved out with a solvent. In the case where part of the island component is left undissolved, there are no specific limitations for the favorable adoption of the thermoplastic resin as long as it is dyeable with a dye. Specific examples of such thermoplastic resin to be used for the porous polymethylpentene fiber according to the present invention include, but not limited to, polyester, polyamide, polyvinyl alcohol, polyalkylene glycol, polyolefin, polystyrene, and cellulose derivatives. Of these, polyester and polyamide can be adopted favorably because the state of dispersion with polymethylpentene based resin and the rate of dissolving-out from polymethylpentene conjugate fiber can be controlled easily by changing the copolymerization component and the copolymerization ratio and also because good color developing property can be maintained in the case where part of the island component are left undissolved.
Specific examples of such polyester include, but not limited to, aromatic polyesters such as polyethylene terephthalate, polypropylene terephthalate, polybutylene terephthalate, and polyhexamethylene terephthalate; aliphatic polyesters such as polylactic acid, polyglycolic acid, polyethylene adipate, polypropylene adipate, polybutylene adipate, polyethylene succinate, polypropylene succinate, polybutylene succinate, polyethylene sebacate, polypropylene sebacate, polybutylene sebacate, and polycaprolactone, and copolymerized polyesters produced by copolymerizing these polyesters with copolymerization components. Of these, polylactic acid can be adopted favorably to produce polymethylpentene conjugate fiber because it has a low refractive index and ensures good color developing property when dyed. Polylactic acid and copolymers of polyethylene terephthalate with 5-sodium sulfoisophthalic acid can also be adopted favorably to produce porous polymethylpentene fiber because they have high spinning operability, shows a high rate of dissolving-out into an alkali aqueous solution, and ensures good color developing property in the case where part of the island component are left undissolved.
Specific examples of such copolymerization components to be copolymerized with polyester include, but not limited to, aromatic dicarboxylic acids such as phthalic acid, isophthalic acid, terephthalic acid, 5-sodium sulfoisophthalic acid, 1,5-naphthalene dicarboxylic acid, 2,6-naphthalene dicarboxylic acid, 2,2′-biphenyl dicarboxylic acid, 3,3′-biphenyl dicarboxylic acid, 4,4′-biphenyl dicarboxylic acid, anthracene dicarboxylic acid; aliphatic dicarboxylic acids such as malonic acid, fumaric acid, maleic acid, succinic acid, itaconate, adipic acid, azelaic acid, sebacic acid, 1,11-undecane dicarboxylic acid, 1,12-dodecane dicarboxylic acid, 1,14-tetradecane dicarboxylic acid, 1,18-octadecane dicarboxylic acid, 1,2-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, dimer acid; aromatic diols such as catechol, naphthalene diols, and bisphenol; and aliphatic diols such as ethylene glycol, trimethylene glycol, tetramethylene glycol, hexamethylene glycol, diethylene glycol, polyethylene glycol, polypropylene glycol, neopentyl glycol, and cyclohexanedimethanol. These copolymerization components may be used singly, or two or more thereof may be used in combination.
Specific examples of such polyamide include, but not limited to, aromatic polyamides such as nylon 6T, nylon 9T, and nylon 10T; aliphatic polyamides such as nylon 4, nylon 6, nylon 11, nylon 12, nylon 46, nylon 410, nylon 66, and nylon 610; and copolymerized polyamides produced by copolymerizing these polyamides with copolymerization components.
Specific examples of such copolymerization components to be copolymerized with polyamide include, but not limited to, aromatic diamines such as meta-phenilene diamine, para-phenylene diamine, meta-xylylene diamine, and para-xylylene diamine; aliphatic diamines such as 1,2-ethylene diamine, 1,3-trimethylene diamine, 1,4-tetramethylene diamine, 1,5-pentamethylene diamine, 2-methyl-1,5-pentamethylene diamine, 1,6-hexamethylene diamine, 1,7-heptamethylene diamine, 1,8-octamethylene diamine, 1,9-nonamethylene diamine, 2-methyl-1,8-octamethylene diamine, 1,10-decamethylene diamine, 1,11-undecamethylene diamine, 1,12-dodecamethylene diamine, 1,13-tridecamethylene diamine, 1,16-hexadecamethylene diamine, 1,18-octadecamethylene diamine, 2,2,4-trimethyl hexamethylene diamine, piperazine, and cyclohexane diamine; aromatic dicarboxylic acids such as phthalic acid, isophthalic acid, terephthalic acid, 5-sodium sulfoisophthalic acid, 1,5-naphthalene dicarboxylic acid, 2,6-naphthalene dicarboxylic acid, 2,2′-biphenyl dicarboxylic acid, 3,3′-biphenyl dicarboxylic acid, 4,4′-biphenyl dicarboxylic acid, and anthracene dicarboxylic acid; and aliphatic dicarboxylic acids such as malonic acid, fumaric acid, maleic acid, succinic acid, itaconate, adipic acid, azelaic acid, sebacic acid, 1,11-undecane dicarboxylic acid, 1,12-dodecane dicarboxylic acid, 1,14-tetradecane dicarboxylic acid, 1,18-octadecane dicarboxylic acid, 1,2-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, and dimer acid. These copolymerization components may be used singly, or two or more thereof may be used in combination.
Examples of such thermoplastic polyacrylonitrile include copolymers of acrylonitrile with a copolymerization component.
Specific examples of such copolymerization components to be copolymerized with thermoplastic polyacrylonitrile include, but not limited to, acrylic acid esters such as methyl acrylate, ethyl acrylate, acrylic acid propyl, and butyl acrylate; methacrylic acid esters such as methyl methacrylate, ethyl methacrylate, propyl methacrylate, and butyl methacrylate; halo-olefins such as vinyl chloride, vinyl fluoride, vinylidene chloride, and vinylidene fluoride; vinyl amides such as acrylamide, methacrylamide, and vinyl pyrolidone; vinyl esters such as vinyl acetate and vinyl propionate; vinyl aromatic compounds such as styrene and vinyl pyridine; vinyl carboxylic acids such as acrylic acid and methacrylic acid; vinyl sulfonic acids such as p-styrene sulfonic acid, allyl sulfonic acid, and methallyl sulfonic acid; and salts of vinyl carboxylic acid or vinyl sulfonic acid such as sodium acrylate, sodium methacrylate, sodium p-styrene sulfonate, sodium allyl sulfonate, and sodium methallyl sulfonate. These copolymerization components may be used singly, or two or more thereof may be used in combination.
Specific examples of such thermoplastic polyacrylonitrile include, but not limited to, acrylonitrile-methyl acrylate copolymer, acrylonitrile-ethyl methacrylate copolymer, acrylonitrile-vinyl chloride copolymer, acrylonitrile-acrylamide copolymer, acrylonitrile-vinyl acetate copolymer, acrylonitrile-styrene copolymer, acrylonitrile-acrylic acid copolymer, acrylonitrile-sodium methacrylate copolymer.
Examples of such thermoplastic polyurethane include polymer compounds produced by three-component reaction of diisocyanate, polyol, and a chain extender.
Specific examples of such diisocyanate include, but not limited to, trimethylene diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, 1,3-bis(isocyanate methyl)cyclohexane, 1,4-bis(isocyanate methyl)cyclohexane, 1,3-cyclohexane diisocyanate, 1,4-cyclohexane diisocyanate, 2,2′-diphenyl methane diisocyanate, 2,4′-diphenyl methane diisocyanate, 4,4′-diphenyl methane diisocyanate, 1,5-naphthalene diisocyanate, 2,4-toluene diisocyanate, and 2,6-toluene diisocyanate, diphenyl methane diisocyanate.
Specific examples of such polyol include, but not limited to, polyether polyol, polyester polyol, polycaprolactone polyol, and polycarbonate polyol. Polyether polyol can be produced by ring-opening addition polymerization of low molecular weight polyol or low molecular weight polyamine with alkylene oxide. Polyester polyol can be produced by condensation reaction or ester interchange reaction of low molecular weight polyol with multivalent carboxylic acid, multivalent carboxylic acid ester, multivalent carboxylic anhydride, or multivalent carboxylic acid halide. Polycaprolactone polyol can be produced by ring-opening polymerization of low molecular weight polyol with caprolactone. Polycarbonate polyol can be produced by addition polymerization of low molecular weight polyol with carbonate.
Specific examples of such low molecular weight polyol include, but not limited to, ethylene glycol, propylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, cyclohexanediol, cyclohexanedimethanol, bisphenol, diethylene glycol, dipropylene glycol, glycerin, trimethylolpropane, pentaerythritol, diglycerin, xylitol, sorbitol, mannitol, and dipenta erythritol sucrose. Specific examples of such low molecular weight polyamine include, but not limited to, ethylene diamine, 1,3-propane diamine, 1,4-butane diamine, 1,6-hexamethylene diamine, 1,4-cyclohexane diamine, and hydrazine. Specific examples of such alkylene oxide include, but not limited to, ethylene oxide, propylene oxide, butylene oxide, and tetrahydrofuran. Specific examples of such multivalent carboxylic acid include, but not limited to, oxalic acid, malonic acid, fumaric acid, maleic acid, succinic acid, itaconic acid, adipic acid, phthalic acid, isophthalic acid, terephthalic acid, and dimer acid. Specific examples of such multivalent carboxylic acid esters include, but not limited to, methyl ester and ethyl ester of multivalent carboxylic acid. Specific examples of such multivalent carboxylic anhydride include, but not limited to, oxalic anhydride, succinic anhydride, maleic anhydride, phthalic anhydride, and trimellitic anhydride. Specific examples of such multivalent carboxylic acid halide include, but not limited to, oxalic acid dichloride and adipic acid dichloride. Specific examples of such caprolactone include, but not limited to, ε-caprolactone. Specific examples of such carbonate include, but not limited to, ethylene carbonate and dimethyl carbonate.
Specific examples of such chain extender include, but not limited to, ethane diols 1,2-propanediol, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, diethylene glycol, and dipropylene glycol.
Such modified polyolefin is preferably a copolymer of α-olefin and a copolymerization component. Such polyolefin, furthermore, may be a homopolymer of α-olefin, or a copolymer of two or more kinds of α-olefin, or a copolymer of α-olefin with a copolymerization component. In terms of structural type, such copolymers may be, but not limited to, block copolymers or graft copolymers.
Such α-olefin preferably contains 2 to 20 carbon atoms and the molecular chain of the α-olefin may be either a straight chain or a branched chain. Specific examples of such α-olefin include, but not limited to, ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicosene, 3-methyl-1-butene, 3-methyl-1-pentene, 4-methyl-1-pentene, 3-ethyl-1-pentene, and 3-ethyl-1-hexene. These α-olefins may be used singly, or two or more thereof may be used in combination.
Copolymerization components that can be adopted favorably for such modified polyolefin include unsaturated compounds that contain a polar functional group with high affinity with dyes. Furthermore, copolymerization components that can be adopted favorably for such polyolefin include unsaturated compounds that contain a polar functional group that works to increase the rate of dissolving-out from polymethylpentene conjugate fiber. Such polar functional group with high affinity with dyes or polar functional groups that work to increase the dissolving-out rate include carboxylic acid group, carboxylic anhydride group, carboxylate group, carboxylic acid ester group, and carboxylic acid amide group. Specific examples of such copolymerization components for modified polyolefin or polyolefin include, but not limited to, unsaturated carboxylic acids such as maleic acid, fumaric acid, itaconic acid, acrylic acid, and methacrylic acid; unsaturated carboxylic anhydrides such as maleic anhydride and itaconic anhydride; unsaturated carboxylates such as sodium methacrylate and sodium acrylate; unsaturated carboxylatic acid esters such as vinyl acetate, vinyl propionate, methyl acrylate, ethyl acrylate, methyl methacrylate, and maleic acid monoethyl ester; and unsaturated carboxylic acid amides such as acrylamide and maleic acid monoamide. These copolymerization components may be used singly, or two or more thereof may be used in combination.
Specific examples of such modified polyolefin or polyolefin include, but not limited to, ethylene-maleic acid copolymer, ethylene-fumaric acid copolymer, ethylene-acrylic acid copolymer, ethylene-methacrylic acid copolymer, ethylene-acrylic acid-sodium methacrylate copolymer, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, acrylic acid grafted polyethylene, maleic anhydride grafted polyethylene, maleic anhydride grafted polypropylene, maleic anhydride grafted ethylene-propylene copolymer, acrylic acid grafted ethylene-propylene copolymer, maleic acid grafted ethylene-propylene-norbornadiene copolymer, and acrylic acid grafted ethylene-vinyl acetate copolymer.
The polyvinyl chloride may be either a homopolymer of vinyl chloride or a copolymer of vinyl chloride and a copolymerization component.
Specific examples of such copolymerization components for polyvinyl chloride include, but not limited to, vinyl esters such as vinyl acetate and vinyl propionate; acrylic acid esters such as acrylic acid propyl and butyl acrylate; and olefins such as ethylene and propylene. These copolymerization components may be used singly, or two or more thereof may be used in combination.
A cellulose derivative is a compound formed by replacing at least part of the three hydroxyl groups existing in glucose units that constitute cellulose with other functional groups. Examples thereof include, but not limited to, single cellulose ester composed of cellulose and one ester group bonded thereto, mixed cellulose ester composed of cellulose and a plurality of ester groups bonded thereto, single cellulose ether composed of cellulose and one ether group bonded thereto, mixed cellulose ether composed of cellulose and a plurality of ether groups bonded thereto, and cellulose ether ester composed of cellulose and one or a plurality of ether groups and ester groups bonded thereto. There are no specific limitations on the degree of substitution of these cellulose derivatives, and a cellulose derivative with an appropriate degree of substitution may be selected from the viewpoint of its melt viscosity, thermoplasticity, and solubility in the solvent to be used for dissolving out the island component. If a cellulose derivative to be used does not show thermoplasticity, a plasticizer may be added to the cellulose derivative with the aim of improving its high temperature flowability.
Specific examples of such cellulose derivatives include, but not limited to, single cellulose esters such as cellulose acetate, cellulose propionate, cellulose butyrate, cellulose valerate, and cellulose stearate; mixed cellulose esters such as, cellulose acetate propionate, cellulose acetate butyrate, cellulose acetate valerate, cellulose acetate caproate, cellulose propionate butyrate, and cellulose acetate propionate butyrate; single cellulose ethers such as methyl cellulose, ethyl cellulose, propyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, and carboxymethyl cellulose; mixed cellulose ethers such as methyl ethyl cellulose, methyl propyl cellulose, ethyl propyl cellulose, hydroxymethyl methyl cellulose, hydroxymethyl ethyl cellulose, hydroxypropyl methyl cellulose, hydroxyethyl methyl cellulose, and hydroxypropyl methyl cellulose; and cellulose ether esters such as methyl cellulose acetate, methyl cellulose propionate, ethyl cellulose acetate, ethyl cellulose propionate, propyl cellulose acetate, propyl cellulose propionate, hydroxymethyl cellulose acetate, hydroxymethyl cellulose propionate, hydroxyethyl cellulose acetate, hydroxyethyl cellulose propionate, hydroxypropyl cellulose acetate, hydroxypropyl cellulose propionate, carboxymethyl cellulose acetate, and carboxymethyl cellulose propionate.
Such polyvinyl alcohol may be either a homopolymer of vinyl alcohol or a copolymer of vinyl alcohol with a copolymerization component.
Specific examples of such copolymerization components for polyvinyl alcohol include, but not limited to, vinyl esters such as vinyl acetate, vinyl propionate and vinyl pivalate; vinyl carboxylic acids such as maleic acid, itaconic acid; vinyl carboxylic anhydrides such as maleic anhydride and itaconic anhydride; olefins such as ethylene and propylene; vinyl amides such as acrylamide, methacrylamide, and vinyl pyrolidone; and vinyl sulfonic acids such as p-styrene sulfonic acid, allyl sulfonic acid, and methallyl sulfonic acid. These copolymerization components may be used singly, or two or more thereof may be used in combination.
Specific examples of such polyalkylene glycol include, but not limited to, homopolymers such as polyethylene glycol, polypropylene glycol, and polytetramethylene glycol; and copolymers such as polyethylene glycol-polypropylene glycol copolymer and polyethylene glycol-polybutylene glycol copolymer.
Such polystyrene may be either a homopolymer of styrene or a copolymer of styrene with a copolymerization component. Specific examples of such copolymerization components for polystyrene include, but not limited to, unsaturated carboxylic acids such as maleic acid, fumaric acid, itaconic acid, acrylic acid, and methacrylic acid; unsaturated carboxylic anhydrides such as maleic anhydride and itaconic anhydride; unsaturated carboxylates such as sodium methacrylate and sodium acrylate; unsaturated carboxylic acid esters such as vinyl acetate, vinyl propionate, methyl acrylate, ethyl acrylate, methyl methacrylate, and maleic acid monoethyl ester; and unsaturated carboxylic acid amides such as acrylamide and maleic acid monoamide. These copolymerization components may be used singly, or two or more thereof may be used in combination.
Thermoplastic resin used for the present invention preferably has a melting point or a flow start temperature under heat in the range of 180 to 270° C. The use of thermoplastic resin with a melting point or a flow start temperature under heat of 180° C. or more is preferable because in that case, the thermoplastic resin does not undergo heat degradation during melt spinning for producing a composite structure with polymethylpentene based resin, leading to conjugate fiber and porous polymethylpentene fiber with good mechanical characteristics. The use of thermoplastic resin with a melting point of 270° C. or less is preferable because in that case, the polymethylpentene based resin does not undergo heat degradation during melt spinning for producing a composite structure with the thermoplastic resin, leading to polymethylpentene conjugate fiber and porous polymethylpentene fiber with good mechanical characteristics. The thermoplastic resin more preferably has a melting point of 190 to 265° C., still more preferably 200 to 260° C.
For the present invention, the melting point and flow start temperature under heat can be measured by the following method. The melting point of the aforementioned polymethylpentene based resin and the melting point of the above thermoplastic resin can be measured by using a differential scanning calorimeter (DSC) (for example, DSC7 differential scanning calorimeter manufactured by Perkin-Elmer). Specifically, a specimen of about 10 mg is heated from 30° C. to 280° C. in a nitrogen atmosphere at a heating rate of 15° C./min and maintained at 280° C. for 3 minutes to remove heat history from the specimen. Subsequently, it is cooled from 280° C. to 30° C. at a cooling rate of 15° C./min, maintained at 30° C. for 3 minutes, and heated from 30° C. to 280° C. at a heating rate 15° C./min, and the peak temperature of the endothermic peak observed during the second heating process is assumed to be its melting point (° C.). Here, three measurements are made for a specimen, and their average is taken as the melting point. However, if the peak width of the endothermic peak is larger than 50° C. or if the absorbed heat quantity of the endothermic peak is less than 5 J/g, it is assumed that the specimen does not show a melting point and the flow start temperature under heat is determined by the following method. Polymethylpentene based resin or thermoplastic resin that is vacuum-dried is subjected to measurement under a load of 2.16 kg using a flow tester (for example, CFT-500D flow tester manufactured by Shimadzu Corporation) having a die with a pore size of 1.0 mm and hole length of 2.0 mm. When a specimen of 1.0 g is heated up from 40° C. at a heating rate of 6° C./min, the temperature at which the plunger starts descending is assumed to be the flow start temperature under heat (° C.). Here, three measurements are made for a specimen, and their average is taken as its flow start temperature under heat.
With respect to the melt viscosity of thermoplastic resin to be used for the present invention, the melt viscosity of thermoplastic resin can be adopted favorably if it is in the range of the melt viscosity ratio ηb/ηa where ηa and ηb represent the melt viscosity of polymethylpentene based resin and the melt viscosity of thermoplastic resin, respectively, as described later. For the present invention, thermoplastic resin having a molecular weight and polymerization degree that suit the melt viscosity of the thermoplastic resin can be selected appropriately.
There are no specific limitations on the specific gravity of the thermoplastic resin used for the present invention, but it is preferable to select an appropriate content ratio to polymethylpentene based resin so that the specific gravities of the resulting polymethylpentene conjugate fiber and porous polymethylpentene fiber are in the preferable range described later because in that case, it is possible to obtain polymethylpentene conjugate fiber and porous polymethylpentene fiber having a light weight corresponding to the specific gravity of the thermoplastic resin.
Thermoplastic resin used for the present invention may be one that has been modified through various methods by adding minor additives. Specific examples of such minor additives include, but not limited to, compatibilizer, plasticizer, ultraviolet absorber, infrared ray absorbent, fluorescent brightening agent, mold releasing agent, antibacterial agent, nuclear formation agent, thermal stabilizer, antioxidant, antistatic agent, color protection agent, adjustor, delustering agent, antifoam agent, antiseptic agent, gelatinizer, latex, filler, ink, coloring agent, dye, pigments, and perfume. These minor additives may be used singly, or a plurality thereof may be used in combination.
For the present invention, a compatibilizer may be used as needed for the purpose of improving the dispersibility of the island component in the sea component, controlling the dispersion state, and improving the interfacial adhesion between the sea component and island component. When a sea-island structure is produced by melt spinning, bulges called ballas tend to be formed immediately below the nozzle to make the thinning deformation of the fiber unstable and accordingly, a compatibilizer may be used with the aim of improving the spinning operability through, for example, prevention of thread breakage caused by the ballas.
For the present invention, a compatibilizer may be added to either the sea component or the island component or to both the sea component and the island component. A compatibilizer may be selected appropriately to suit the type of the thermoplastic resin used, copolymerization component, copolymerization ratio, and content ratio between sea component and island component. Different compatibilizers may be used singly, or a plurality thereof may be used in combination.
A compatibilizer to be used for the present invention may be a compound having a molecular structure that contains both a hydrophobic component with high affinity with polymethylpentene based resin, which is highly hydrophobic, and a component with high affinity with the thermoplastic resin of the island component. Alternatively, a compound having a molecular structure that contains both a hydrophobic component with high affinity with polymethylpentene based resin and a functional group reactive with the thermoplastic resin of the island component may also be used.
Specific examples of the hydrophobic component contained in a compatibilizer include, but not limited to, polyethylene, polypropylene, polymethylpentene, polystyrene, ethylene-propylene copolymer, ethylene-butylene copolymer, propylene-butylene copolymer, and styrene-ethylene-butylene-styrene copolymer.
Specific examples of such a component with high affinity with thermoplastic resin or such a functional group reactive with thermoplastic resin include, but not limited to, carboxylic acid group, carboxylic anhydride group, carboxylate group, carboxylic acid ester group, carboxylic acid amide group, amino group, imino group, alkoxy silyl group, silanol group, silyl ether group, hydroxyl group, and epoxy group.
Specific examples of such a compatibilizer include, but not limited to, maleic acid modified polyethylene, maleic anhydride modified polypropylene, maleic anhydride modified polymethylpentene, epoxy modified polystyrene, maleic anhydride modified styrene-ethylene-butylene-styrene copolymer, amino modified styrene-ethylene-butylene-styrene copolymer, imino modified styrene-ethylene-butylene-styrene copolymer.
For the present invention, the compatibilizer to be added preferably accounts for 0.1 to 15 wt % relative to the total quantity of polymethylpentene based resin and thermoplastic resin which accounts for 100 wt %. A compatibilizer content of 0.1 wt % or more is preferable because in that case, this has the effect of increasing the compatibility between the sea component and the island component, leading to an improvement in spinning operability through, for example, prevention of thread breakage. This is preferable also because the increase in spinning operability causes a decrease in the dispersion diameter of island domains, leading to the development of deep, vivid colors when the resulting polymethylpentene conjugate fiber is dyed. Furthermore, this is preferable because dissolving out the island component causes a decrease in the pore diameter, leading to porous polymethylpentene fiber that is resistant to pore deformation and collapse. On the other hand, a compatibilizer content of 15 wt % or less is preferable because this serves to prevent the spinning operability from being destabilized by excessive compatibilizer. This is preferable also because the resulting polymethylpentene conjugate fiber can maintain the good fiber characteristics, appearance, and texture that originate from the polymethylpentene based resin and thermoplastic resin. The compatibilizer content is more preferably 0.5 to 12 wt % and still more preferably 1 to 10 wt %.
Described below is the polymethylpentene conjugate fiber according to the present invention. The polymethylpentene conjugate fiber according to the present invention preferably has a specific gravity of 0.83 to 1.1. If fiber is produced from the polymethylpentene based resin, which has a specific gravity of 0.83, alone, the resulting fiber has the disadvantage of being unable to be dyed though being very light in weight. The present invention is designed to combine polymethylpentene based resin with a low specific gravity and dyeable thermoplastic resin to produce a conjugate fiber so as to impart colors to the lightweight polymethylpentene based resin. The specific gravity of the polymethylpentene conjugate fiber changes depending on the specific gravity and content of the thermoplastic resin to be combined. The specific gravity of the polymethylpentene conjugate fiber should be as low as possible from the viewpoint of lightness, and it is preferably 1.1 or less. If the specific gravity of the polymethylpentene conjugate fiber is 1.1 or less, it is preferable because the lightness of the polymethylpentene based resin and the color developing property of the thermoplastic resin can be maintained simultaneously. The specific gravity of the polymethylpentene conjugate fiber is more preferably 0.83 to 1.05 and still more preferably 0.83 to 1.0.
For both unstretched and stretched yarns, there are no specific limitations on the total fineness of the polymethylpentene conjugate fiber according to the present invention, but it is preferably 10 to 500 dtex. If the polymethylpentene conjugate fiber has a total fineness of 10 dtex or more, it is preferable because the spinning operability and process-passing capability in high-order processing steps will be high and the fiber will not suffer significant fuzzing during use, leading to high durability. On the other hand, if the polymethylpentene conjugate fiber has a total fineness of 500 dtex or less, it is preferable because the fiber and fiber structures will not suffer a decrease in flexibility. The total fineness of the polymethylpentene conjugate fiber is more preferably 30 to 400 dtex and still more preferably 50 to 300 dtex.
For both unstretched and stretched yarns, there are no specific limitations on the strength of the polymethylpentene conjugate fiber according to the present invention, but it is preferably 0.5 to 5.0 cN/dtex. The strength of the polymethylpentene conjugate fiber should be as high as possible from the viewpoint of mechanical characteristics, and it is preferably 0.5 cN/dtex or more. If the polymethylpentene conjugate fiber has a strength of 0.5 cN/dtex or more, it is preferable because it ensures a high spinning operability and high process-passing capability in high-order processing steps and also because fiber and fiber structures with high durability can be obtained. The strength of the polymethylpentene conjugate fiber is more preferably 0.7 to 5.0 cN/dtex and still more preferably 1.0 to 5.0 cN/dtex.
For both unstretched and stretched yarns, there are no specific limitations on the elongation percentage of the polymethylpentene conjugate fiber according to the present invention, but it is preferably 5 to 300%. If the polymethylpentene conjugate fiber has an elongation percentage of 5% or more, it is preferable because it allows the production of fiber and fiber structures having high wear resistant, leading to depression of fuzzing. On the other hand, if the unstretched yarns in the polymethylpentene conjugate fiber have an elongation percentage of 300% or less, it is preferable because it ensures a high handleability during the stretching and mechanical characteristics can be improved by the stretching. Furthermore, if the stretched yarns in the polymethylpentene conjugate fiber have an elongation percentage of 30% or less, it is preferable because it allows the production of fiber and fiber structures with high dimensional stability. If the polymethylpentene conjugate fiber is formed of unstretched yarns, its elongation percentage is preferably 8 to 280% and more preferably 10 to 250%. If the polymethylpentene conjugate fiber is formed of stretched yarns, its elongation percentage is more preferably 8 to 28% and still more preferably 10 to 25%.
For both unstretched and stretched yarns, there are no specific limitations on the initial tensile resistance of the polymethylpentene conjugate fiber according to the present invention, but its initial tensile resistance as measured according to 8.10 of JIS L 1013 (1999) is preferably 10 to 100 cN/dtex. If the polymethylpentene conjugate fiber has an initial tensile resistance of 10 cN/dtex or more, it is preferable because it ensures a high handleability and process-passing capability in high-order processing steps. On the other hand, if the polymethylpentene conjugate fiber has an initial tensile resistance of 100 cN/dtex or less, it is preferable because the fiber and fiber structures will not suffer a decrease in flexibility. The initial tensile resistance of the polymethylpentene conjugate fiber is more preferably 15 to 80 cN/dtex and still more preferably 20 to 60 cN/dtex.
For both unstretched and stretched yarns, there are no specific limitations on the average fiber diameter of the polymethylpentene conjugate fiber according to the present invention, but it is preferably 3 to 100 μm. If the polymethylpentene conjugate fiber has an average fiber diameter of 3 μm or more, it is preferable because it ensures a high spinning operability and a high process-passing capability in high-order processing, allowing the formation of polymethylpentene conjugate fiber with good mechanical characteristics. On the other hand, if the polymethylpentene conjugate fiber has an average fiber diameter of 100 μm or less, it is preferable because the fiber and fiber structures will not suffer a decrease in flexibility. The average fiber diameter of the polymethylpentene conjugate fiber is more preferably 5 to 70 μm and still more preferably 7 to 50 μm.
In the polymethylpentene conjugate fiber according to the present invention, the dispersion diameter of the island domains in the fiber cross section is preferably 0.001 to 2 μm. The dispersion diameter of the island domains in the fiber cross section should be as small as possible from the viewpoint of color developing property, but it is preferably 2 μm or less. If the dispersion diameter of the island domains in the fiber cross section of the polymethylpentene conjugate fiber is 2 μm or less, it is preferable because it ensures stable discharge from the spinning nozzle during melt spinning, leading to high spinning operability. Furthermore, it is preferable also because good color developing property is achieved by the thermoplastic resin of the island component dispersed in the polymethylpentene based resin of the sea component. The dispersion diameter of the island domains in the fiber cross section of the polymethylpentene conjugate fiber is more preferably 0.001 to 1.5 μm and still more preferably 0.001 to 1.0 μm.
In the polymethylpentene conjugate fiber according to the present invention, the coefficient of variation CV of the dispersion diameter of the island domains in the fiber cross section is preferably 1 to 50%. The method to be used for measuring the coefficient of variation CV will be described in detail later, but the coefficient of variation CV is an indicator of uniformity and is calculated by dividing the standard deviation by the average. In the polymethylpentene conjugate fiber according to the present invention, the coefficient of variation CV of the dispersion diameter of the island domains in the fiber cross section should be as small as possible from the viewpoint of color developing property, but technically its lower limit is 1%. If the coefficient of variation CV of the dispersion diameter of the island domains in the fiber cross section is 50% or less, it is preferable because good color developing property is achieved by the thermoplastic resin of the island component dispersed in the polymethylpentene based resin of the sea component. The coefficient of variation CV of the dispersion diameter of the island domains in the fiber cross section is more preferably 1 to 45%, still more preferably 1 to 40%, particularly preferably 1 to 30%, and extremely preferably 1 to 20%.
For the polymethylpentene conjugate fiber according to the present invention, there are no specific limitations on the shape of the fiber cross section, and the cross section may be either perfect circular or non-circular. Specific examples of such non-circular shapes include, but not limited to, multilobar, polygonal, flattened, elliptic, C-shaped, H-shaped, S-shaped, T-shaped, W-shaped, X-shaped, Y-shaped, grid-like, double-crossed, and hollow.
For the polymethylpentene conjugate fiber according to the present invention, there are no specific limitations on the shape of the island domains in the fiber cross section, and the section may be either perfect circular or non-circular. Specific examples of such non-circular section shapes include, but not limited to, multilobar, polygonal, flattened, T-shaped, X-shaped, and Y-shaped.
Described below is the porous polymethylpentene fiber according to the present invention.
The porous polymethylpentene fiber according to the present invention may contain thermoplastic resin. The porous polymethylpentene fiber according to the present invention can be produced by preparing a conjugate fiber having a sea-island structure composed of polymethylpentene based resin as sea component and thermoplastic resin as island component and dissolving out the island component to form pores. If pores are formed while leaving part of the island component, the thermoplastic resin will be left along the pore peripheries. Since polymethylpentene based resin is high in transparency and low in refractive index, vivid colors can be developed in the inner parts of the fiber by dyeing the thermoplastic resin left along the peripheries of pores in inner parts of the fiber, indicating that color development property can be imparted to the porous polymethylpentene fiber.
In the porous polymethylpentene fiber according to the present invention, the coefficient of variation CV of the pore diameter in the fiber cross section is 1 to 50%. The method to be used for measuring the coefficient of variation CV will be described in detail later, but the coefficient of variation CV is an indicator of uniformity and is calculated by dividing the standard deviation by the average. In the porous polymethylpentene fiber according to the present invention, the coefficient of variation CV of the pore diameter in the fiber cross section should be as small as possible from the viewpoint of durability, but technically its lower limit is 1%. If the coefficient of variation CV of the pore diameter in the fiber cross section is 50% or less, it is preferable because it ensures a high uniformity in pore size and depression of pore deformation and collapse due to stress concentrations, allowing the production of porous polymethylpentene fiber with a high pore resistance to external force. Furthermore, if the porous polymethylpentene fiber contains thermoplastic resin and has high uniformity in pore size, it is preferable because uniform color development can be achieved by dyeing the thermoplastic resin. The coefficient of variation CV of the pore diameter in the fiber cross section is more preferably 1 to 45%, still more preferably 1 to 40%, particularly preferably 1 to 30%, and extremely preferably 1 to 20%.
In the porous polymethylpentene fiber according to the present invention, the average diameter of the pores in the fiber cross section is preferably 0.001 to 2 μm. If the average diameter of the pores in the fiber cross section is 0.001 μm or more, it is preferable because the pores can serve for weight reduction, heat insulation, and cushioning. Furthermore, if the porous polymethylpentene fiber contains thermoplastic resin and the thermoplastic resin is finely dispersed in the inner parts of the fiber, it is preferable because dyeing of the thermoplastic resin allows the transmitted beams and reflected beams from inside the fiber to be mixed randomly to give vivid colors. On the other hand, if the average diameter of the pores in the fiber cross section is 2 μm or less, it is preferable because pore deformation and collapse are depressed, leading to a high pore resistance to external force and high durability. The average diameter of the pores in the fiber cross section of the porous polymethylpentene fiber is more preferably 0.005 to 1.5 μm and still more preferably 0.01 to 1.0 μm.
The porous polymethylpentene fiber according to the present invention preferably has a porosity of 0.1 to 70%. A porosity of 0.1% or more is preferable because the polymethylpentene based resin, which is originally low in specific gravity, not only can be made still lighter but also can be imparted with heat insulation property and cushioning property. On the other hand, a porosity of 70% or less is preferable because the fiber and fiber structures can maintain both mechanical strength and other good properties such as lightweight, heat insulation, and cushioning. The porosity of the porous polymethylpentene fiber is more preferably 0.5 to 60%, still more preferably 1 to 50%, particularly preferably 5 to 30%, and extremely preferably 10 to 20%.
The porous polymethylpentene fiber according to the present invention preferably has a specific gravity of 0.25 to 0.80. Even when fiber is produced from the polymethylpentene based resin, which has a specific gravity of 0.83, alone, the resulting fiber is fairly light in weight. For the present invention, pores are formed in fiber to make the fiber porous. Accordingly, polymethylpentene fiber with a low specific gravity can be made still lighter and the pores serve to impart heat insulation property, cushioning property, etc. The specific gravity of the porous polymethylpentene fiber changes depending on the porosity of the fiber. On the other hand, if the specific gravity of the porous polymethylpentene fiber is 0.25 or more, it is preferable because the fiber and fiber structures can maintain both mechanical strength and other good properties such as lightweight, heat insulation, and cushioning. On the other hand, if the specific gravity of the porous polymethylpentene fiber is 0.80 or less, it is preferable because the polymethylpentene based resin, which is originally low in specific gravity, not only can be made still lighter but also can be imparted with heat insulation property and cushioning property. The specific gravity of the porous polymethylpentene fiber is more preferably 0.33 to 0.75 and still more preferably 0.42 to 0.70.
There are no specific limitations on the total fineness of the porous polymethylpentene fiber according to the present invention, which therefore may be adjusted appropriately to suite particular uses and required characteristics, but it is preferably 10 to 500 dtex. If the porous polymethylpentene fiber has a total fineness of 10 dtex or more, it is preferable because it ensures low thread breakage frequency and high process-passing capability and the fiber will not suffer significant fuzzing during use, leading to high durability. On the other hand, if the porous polymethylpentene fiber has a total fineness of 500 dtex or less, it is preferable because the fiber and fiber structures will not suffer a decrease in flexibility. The total fineness of the porous polymethylpentene fiber is more preferably 30 to 400 dtex and still more preferably 50 to 300 dtex.
There are no specific limitations on the strength of the porous polymethylpentene fiber according to the present invention, which therefore may be adjusted appropriately to suite particular uses and required characteristics, but it is preferably 0.5 to 5.0 cN/dtex. The strength of the porous polymethylpentene fiber should be as high as possible from the viewpoint of mechanical characteristics, and it is preferably 0.5 cN/dtex or more. If the porous polymethylpentene fiber has a strength of 0.5 cN/dtex or more, it is preferable because it ensures low thread breakage frequency, high process-passing capability, and high durability. The strength of the porous polymethylpentene fiber is more preferably 0.7 to 5.0 cN/dtex and still more preferably 1.0 to 5.0 cN/dtex.
There are no specific limitations on the elongation percentage of the porous polymethylpentene fiber according to the present invention, which therefore may be adjusted appropriately to suite particular uses and required characteristics, but it is preferably 5 to 300%. If the porous polymethylpentene fiber has an elongation percentage of 5% or more, it is preferable because it allows the production of fiber and fiber structures having high wear resistant, leading to depression of fuzzing and high durability. On the other hand, if the porous polymethylpentene fiber has an elongation percentage of 300% or less, it is preferable because it allows the production of fiber and fiber structures with high dimensional stability. If stretching is performed during the production of porous polymethylpentene fiber, the elongation percentage is more preferably 8 to 28% and still more preferably 10 to 25%.
There are no specific limitations on the initial tensile resistance of the porous polymethylpentene fiber according to the present invention, which therefore may be adjusted appropriately to suite particular uses and required characteristics, but the initial tensile resistance as measured according to 8.10 of JIS L 1013 (1999) is preferably 10 to 100 cN/dtex. If the porous polymethylpentene fiber has an initial tensile resistance of 10 cN/dtex or more, it is preferable because it ensures a high process-passing capability and high handleability as well as good mechanical characteristics. On the other hand, if the porous polymethylpentene fiber has an initial tensile resistance of 100 cN/dtex or less, it is preferable because the fiber and fiber structures produced therefrom will not suffer a decrease in flexibility. The initial tensile resistance of the porous polymethylpentene fiber is more preferably 15 to 80 cN/dtex and still more preferably 20 to 60 cN/dtex.
There are no specific limitations on the average fiber diameter of the porous polymethylpentene fiber according to the present invention, which therefore may be adjusted appropriately to suite particular uses and required characteristics, but the average fiber diameter is preferably 3 to 100 μm. If the porous polymethylpentene fiber has an average fiber diameter of 3 μm or more, it is preferable because it ensures a high process-passing capability and high handleability as well as excellent durability. On the other hand, if the porous polymethylpentene fiber has an average fiber diameter of 100 μm or less, it is preferable because the fiber and fiber structures will not suffer a decrease in flexibility. The average fiber diameter of the porous polymethylpentene fiber is more preferably 5 to 70 μm and still more preferably 7 to 50 μm.
For the porous polymethylpentene fiber according to the present invention, there are no specific limitations on the shape of the fiber cross section, and the cross section may be either perfect circular or non-circular. Specific examples of non-circular shapes include, but not limited to, multilobar, polygonal, flattened, elliptic, C-shaped, H-shaped, S-shaped, T-shaped, W-shaped, X-shaped, and Y-shaped.
For the porous polymethylpentene fiber according to the present invention, there are no specific limitations on the shape of the pores in the fiber cross section, and the section may be either perfect circular or non-circular. Specific examples of such non-circular section shapes include, but not limited to, multilobar, polygonal, flattened, elliptic, T-shaped, X-shaped, and Y-shaped.
The polymethylpentene conjugate fiber and porous polymethylpentene fiber according to the present invention may be ones that have been modified through various methods by adding minor additives. Specific examples of such minor additives include, but not limited to, compatibilizer, plasticizer, ultraviolet absorber, infrared ray absorbent, fluorescent brightening agent, mold releasing agent, antibacterial agent, nuclear formation agent, thermal stabilizer, antioxidant, antistatic agent, color protection agent, adjustor, delustering agent, antifoam agent, antiseptic agent, gelatinizer, latex, filler, ink, coloring agent, dye, pigments, and perfume. These minor additives may be used singly, or a plurality thereof may be used in combination.
There are no specific limitations on the form of the polymethylpentene conjugate fiber and porous polymethylpentene fiber according to the present invention, which therefore, may be in the form of monofilament, multifilament, or staple.
As in the case of other general fibers, the polymethylpentene conjugate fiber and porous polymethylpentene fiber according to the present invention may be processed by, for example, stretching, false-twisting, and twining, and may also be woven and knitted by methods generally used for fiber.
There are no specific limitations on the form of the fiber structures to be produced from the polymethylpentene conjugate fiber and porous polymethylpentene fiber according to the present invention, which therefore, may be processed by generally known methods into, for example, woven fabric, knitted fabric, pile fabric, nonwoven fabric, spun yarn, and wadding. Fiber structures to be produced from the polymethylpentene conjugate fiber and porous polymethylpentene fiber according to the present invention may be of any weave or knit structure and may preferably be processed by plain weaving, diagonal weaving, sateen weaving, or their modified weaving techniques, or warp knitting, weft knitting, circular knitting, lace stitching, or their modified knitting techniques.
The polymethylpentene conjugate fiber and porous polymethylpentene fiber according to the present invention may be produced by combining polymethylpentene conjugate fiber or porous polymethylpentene fiber with other fibers by mixed weaving or mixed knitting to form fiber structures or preparing combined filament yarns from polymethylpentene conjugate fiber or porous polymethylpentene fiber along with other fibers, followed by processing them into fiber structures.
Described below are production methods for the polymethylpentene conjugate fiber and porous polymethylpentene fiber according to the present invention.
The polymethylpentene conjugate fiber according to the present invention has a sea-island structure including polymethylpentene based resin as sea component and thermoplastic resin as island component. On the other hand, the porous polymethylpentene fiber according to the present invention can be produced by dissolving out at least part of the island component from the polymethylpentene conjugate fiber having a sea-island structure including polymethylpentene based resin as sea component and thermoplastic resin as island component. Forming pores by completely dissolving out the island component is preferable because highly lightweight porous polymethylpentene fiber formed only of the polymethylpentene based resin can be obtained. On the other hand, if part of the island component is left, instead of dissolving out the island component completely, in forming pores, porous polymethylpentene fiber composed of both polymethylpentene based resin and thermoplastic resin is obtained. This is preferable not only because of the lightness, but also because colors can be imparted to the porous polymethylpentene fiber by dyeing the thermoplastic resin.
For the present invention, useful methods for forming such a sea-island structure include, but not limited to, sea-island conjugate spinning, which is a kind of melt spinning, and polymer alloy type spinning. In general, when sea-island conjugate spinning is performed, the subsequent dissolving-out of the island component does not produce through-holes extending from the interior to the exterior (lateral face) of the porous polymethylpentene fiber whereas when polymer alloy type spinning is performed, the subsequent dissolving-out of the island component produces through-holes extending from the interior to the exterior (lateral face) of the porous polymethylpentene fiber, with the features of the through-holes depending on the content ratio and melt viscosity ratio between the sea component and the island component.
For the polymethylpentene conjugate fiber according to the present invention, the content ratio (by weight) between the sea component and the island component is preferably 20/80 to 99/1. If the sea component has a content of 20 wt % or more, it is preferable because abnormalities such as joining of island domains does not occur during conjugate formation by melt spinning, leading to stable discharge from the spinning nozzle. Furthermore, since thermoplastic resin with good color developing property is scattered in polymethylpentene based resin with a low refractive index, it is preferable because deep, vivid colors can be developed and also because lightness, which is an advantageous feature of the polymethylpentene based resin, can be imparted to the thermoplastic resin. On the other hand, if the sea component accounts for 99 wt % or less, that is, the island component accounts for 1 wt % or more, it is preferable because dyeing of many island domains scattered in the sea domain allows the transmitted beams through island domains and the reflected beams from island domains to be mixed randomly to give deep, vivid colors. The content ratio (by weight) between the sea component and the island component is more preferably 30/70 to 95/5 and still more preferably 40/60 to 90/10.
For the polymethylpentene conjugate fiber to be used to produce the porous polymethylpentene fiber according to the present invention, the content ratio (by weight) between the sea component and the island component is preferably 30/70 to 99.9/0.1. If the sea component has a content of 30 wt % or more, it is preferable because abnormalities such as joining of island domains does not occur during conjugate formation by melt spinning, leading to stable discharge from the spinning nozzle. Furthermore, it is preferable also because the fiber and fiber structures can maintain both mechanical strength and other good properties such as lightweight, heat insulation, and cushioning. On the other hand, if the sea component accounts for 99.9 wt % or less, that is, the island component accounts for 0.1 wt % or more, it is preferable because the fiber can be made porous by dissolving out the island component to allow the polymethylpentene based resin with a low specific gravity to be made still lighter and in addition, heat insulation property, cushioning property, etc., can be imparted. The content ratio (by weight) between the sea component and the island component is more preferably 40/60 to 99/1 and still more preferably 50/50 to 95/5.
For the polymethylpentene conjugate fiber according to the present invention, the number of island domains in a fiber cross section is preferably 8 to 200 when sea-island conjugate spinning is to be performed. If the number of island domains is 8 or more, it is preferable because the transmitted beams through island domains and the reflected beams from island domains are mixed randomly to give deep, vivid colors, unlike core-sheath type conjugate fibers and sea-island type conjugate fibers in which the number of island domains is less than 8. On the other hand, if the number of island domains is 200 or less, it is preferable because the use of a spinning nozzle of a complicated structure is not necessary, serving to depress the deterioration in spinning operability or mechanical characteristics due to abnormalities such as joining of island domains during conjugate formation. The number of island domains in a fiber cross section is more preferably 16 to 180 and still more preferably 32 to 160 when sea-island conjugate spinning is to be performed. When polymer alloy type spinning is to be performed, there are no specific limitations on the number of island domains in a fiber cross section and from the viewpoint of color developing property, it is preferably as large as possible, particularly 8 or more. If the number of island domains is 8 or more, it is preferable because the transmitted beams through island domains and the reflected beams from island domains are mixed randomly to give deep, vivid colors. The number of island domains in a fiber cross section is more preferably 16 or more and still more preferably 32 or more when polymer alloy type spinning is to be performed.
For the polymethylpentene conjugate fiber to be used to produce the porous polymethylpentene fiber according to the present invention, the number of island domains in a fiber cross section should be at least such as to allow the porous polymethylpentene fiber according to the present invention to be formed. The number of island domains in a fiber cross section is preferably 8 to 200 when sea-island conjugate spinning is to be performed. If the number of island domains is 8 or more, that is, the number of pores is 8 or more, it is preferable because external forces, if applied to the fiber, will be dispersed and pore deformation and collapse due to stress concentrations will be depressed, allowing porous polymethylpentene fiber with a high rate of pore retention to be produced, unlike the case of porous fiber with less than 8 pores. Furthermore, if the porous polymethylpentene fiber contains thermoplastic resin, it is preferable because dyeing of the thermoplastic resin existing in the fiber allows the transmitted beams and reflected beams from inside the fiber to be mixed randomly to give vivid colors. On the other hand, if the number of island domains is 200 or less, it is preferable because the use of a spinning nozzle of a complicated structure is not necessary and the occurrence of abnormalities such as joining of island domains is depressed during conjugate formation, leading to a high uniformity in the dispersion diameter of the island domains, a high pore size uniformity in the porous polymethylpentene fiber resulting from the dissolving-out of the island component, and depression of pore deformation and collapse. Furthermore, if the porous polymethylpentene fiber contains thermoplastic resin and has high uniformity in pore size, it is preferable because uniform color development can be achieved by dyeing the thermoplastic resin. The number of island domains in a fiber cross section is more preferably 16 to 180 and still more preferably 32 to 160 when sea-island conjugate spinning is to be performed. When polymer alloy type spinning is to be performed, there are no specific limitations on the number of island domains in a fiber cross section and from the viewpoint of lightness, heat insulation, and cushioning of the porous polymethylpentene fiber resulting from the dissolving-out of the island component, it is preferably as large as possible, particularly 8 or more. If the number of island domains is 8 or more, that is, the number of pores is 8 or more, it is preferable because external forces, if applied to the fiber, will be dispersed and pore deformation and collapse due to stress concentrations will be depressed, allowing porous polymethylpentene fiber with a high rate of pore retention to be produced, unlike the case of porous fiber with less than 8 pores. Furthermore, if the porous polymethylpentene fiber contains thermoplastic resin, it is preferable because dyeing of the thermoplastic resin existing in the fiber allows the transmitted beams and reflected beams from inside the fiber to be mixed randomly to give deep, vivid colors. The number of island domains in a fiber cross section is more preferably 16 or more and still more preferably 32 or more when polymer alloy type spinning is to be performed.
For the present invention, the melt viscosity ratio (ηb/ηa) between the melt viscosity (ηa) polymethylpentene based resin of the sea component and the melt viscosity (ηb) of the thermoplastic resin of the island component is preferably 0.1 to 4.0. As described later in detail below in relation to the measure method for melt viscosity η, the melt viscosity ratio is defined as the ratio between the melt viscosity of the polymethylpentene based resin and that of the thermoplastic resin determined from measurements taken at the spinning temperature and a shear velocity of 1216 sec −1 . Here, the spinning temperature means the temperature at which the spinning pack is heated in the spinning block of the melt spinning machine. When conjugate fiber is produced by melt spinning, by polymer alloy type spinning in particular, the state of dispersion of the island component in the sea component changes depending on the melt viscosity ratio between the sea component and the island component and therefore, the melt viscosity ratio between the sea component and the island component plays an important role in controlling the dispersion diameter of the island domains in the fiber cross section and the pore diameter in the fiber cross section after dissolving out the island component. Accordingly, the coefficient of variation CV of the dispersion diameter of the island domains in the fiber cross section and the coefficient of variation CV of the pore diameter change depending on the melt viscosity ratio between the sea component and the island component. A melt viscosity ratio (ηb/ηa) of 0.1 or more is preferable because abnormalities such as joining of island domains do not occur during conjugate formation by melt spinning and an increase in the dispersion diameter of the island domains in the fiber cross section is prevented, leading to a sea-island structure with a good dispersion state. It is preferable also because it ensures a high uniformity in the pore diameter in the fiber cross section after dissolving out the island component. Furthermore, if the porous polymethylpentene fiber contains thermoplastic resin and has high uniformity in pore size, it is preferable because uniform color development can be achieved by dyeing the thermoplastic resin. On the other hand, a melt viscosity ratio (ηb/ηa) of 4.0 or less is preferable because it ensures stable discharge from the spinning nozzle during melt spinning, leading to high spinning operability. It is preferable also because the high uniformity in the dispersion diameter of the island domains in the fiber cross section ensures good level dyeing without dyeing specks caused during dyeing and also ensures high uniformity in the pore diameter in the fiber cross section after dissolving out the island component. Furthermore, if the porous polymethylpentene fiber contains thermoplastic resin and has high uniformity in pore size, it is preferable because uniform color development can be achieved by dyeing the thermoplastic resin. The melt viscosity ratio (ηb/ηa) is more preferably 0.3 to 3.0 and still more preferably 0.5 to 2.0.
For the present invention, it is preferable that the polymethylpentene based resin and thermoplastic resin are dried to a water content of 0.3 wt % or less before starting the melt spinning. A water content of 0.3 wt % or less is preferable because foam formation is prevented from being caused by water during the melt spinning, allowing the spinning to be performed stably. The water content is more preferably 0.2 wt % or less and still more preferably 0.1 wt % or less.
The melt spinning can be carried out by a generally known method such as, but not limited to, those described below. For the present invention, sea-island conjugate spinning or polymer alloy type spinning can be adopted favorably to form a sea-island structure.
When sea-island conjugate spinning is to be performed, chips are dried as required and then the chips are supplied to an extruder type or a pressure melter melt type melt spinning machine, where the sea component and the island component are melted separately and weighed by measuring pumps. Subsequently, the melt is introduced into the spinning pack heated in the spinning block and the molten polymer is filtered in the spinning pack, followed by combining the sea component and the island component to form a sea-island structure in a sea-island conjugate formation spinning nozzle and discharging the melt through the spinning nozzle to provide a fiber thread. This method can be adopted favorably.
When polymer alloy type spinning is to be performed, useful methods for discharging the melt through a spinning nozzle to provide a fiber thread include, but not limited to, those described below. In a first example, the sea component and the island component are melt-kneaded in an extruder etc. to prepare composite material and chips thereof are dried as required, followed by supplying the chips to a melt spinning machine, where they are melted, and weighing the melt by a measuring pump. Subsequently, it is introduced into the spinning pack heated in the spinning block and the molten polymer is filtered in the spinning pack, followed by discharging it through the spinning nozzle to provide a fiber thread. In a second example, chips are dried as required and the chips of the sea component and those of the island component are mixed together, followed by supplying the mixed chips to a melt spinning machine, where they are melted, and weighing by a measuring pump. Subsequently, it is introduced into the spinning pack heated in the spinning block and the molten polymer is filtered in the spinning pack, followed by discharging it through the spinning nozzle to provide a fiber thread.
In either the sea-island conjugate spinning process or the polymer alloy type spinning process, the fiber thread discharged from the spinning nozzle is cooled and solidified in a cooling apparatus, taken up by a first godet roller, and wound up by a winder via a second godet roller to provide a wound yarn. Here, a heating cylinder or heat insulation cylinder with a length of 2 to 20 cm may be installed below the spinning nozzle as required to improve the spinning operability, productivity, and mechanical characteristics of the fiber. In addition, an oil feeding apparatus may be used to supply oil to the fiber thread or an entangling machine may be used to entangle the fiber thread.
The spinning temperature used for the melt spinning may be set appropriately to suit the melting point and heat resistance of the polymethylpentene based resin and thermoplastic resin, but it is preferably in the range of 220 to 320° C. A spinning temperature of 220° C. or more is preferable because the elongation viscosity of the fiber thread discharged through the spinning nozzle is maintained sufficiently low to ensure stable discharge and also because the spinning tension is prevented from increasing excessively to depress thread breakage. On the other hand, a spinning temperature of 320° C. or less is preferable because heat decomposition during spinning is depressed and the resulting polymethylpentene conjugate fiber and porous polymethylpentene fiber do not suffer deterioration in mechanical characteristics or coloring. The spinning temperature is more preferably 240 to 300° C. and still more preferably 260 to 280° C.
The spinning speed during the melt spinning may be set appropriately to suit the type, content ratio, and spinning temperature of the thermoplastic resin, but it is preferably 10 to 5,000 m/min. A spinning speed of 10 m/min or more is preferable because the traveling of the thread is maintained stable and thread breakage is depressed. On the other hand, a spinning speed of 5,000 m/min or less is preferable because the fiber thread can be cooled sufficiently to ensure stable spinning. The spinning speed is more preferably 300 to 4,000 m/min and still more preferably 500 to 3,000 m/min.
The fiber taken up after the melt spinning may be stretched to obtain polymethylpentene conjugate fiber and porous polymethylpentene fiber that have intended fiber characteristics. When such stretching is carried out, it may be performed by the two step process in which the fiber is taken up first and stretched subsequently or by the direct spinning and stretching process in which the fiber is stretched continuously without being taken up.
When such stretching is carried out, it may be performed by either a single stage stretching process or a multi-stage stretching process in which the fiber is stretched in two or more stages. There are no specific limitations on the heating method used for the stretching as long as the traveling thread can be heated directly or indirectly. Specific examples of heating methods include, but not limited to, the use of a heating roller, heating pin, heating plate, liquid bath such as warm water and hot water, gas bath such as hot air and steam, and laser. These heating methods may be used singly, or a plurality thereof may be used in combination. Favorable heating methods include contact with a heating roller, contact with a heating pin, contact with a heating plate, and immersion in a liquid bath from the viewpoint of control of the heating temperature, uniform heating of the traveling thread, and simplification of equipment.
When stretching is carried out, the draw ratio may be set appropriately to suit the type and content ratio of the thermoplastic resin and the strength and elongation percentage of the stretched polymethylpentene conjugate fiber and porous polymethylpentene fiber, but it is preferably 1.02 to 7.0. A draw ratio of 1.02 or more is preferable because such stretching can improve mechanical characteristics such as strength and elongation percentage of the polymethylpentene conjugate fiber and porous polymethylpentene fiber. On the other hand, a draw ratio of 7.0 or less is preferable because thread breakage during stretching is depressed to ensure stable stretching. The draw ratio is more preferably 1.2 to 6.0 and still more preferably 1.5 to 5.0.
When stretching is carried out, the stretching temperature may be set appropriately to suit the type and content ratio of the thermoplastic resin and the strength and elongation percentage of the stretched polymethylpentene conjugate fiber and porous polymethylpentene fiber, but it is preferably 50 to 150° C. A stretching temperature of 50° C. or more is preferable because the thread supplied to the stretching step is preheated sufficiently and uniform heat deformation is achieved during the stretching step to ensure the depression of uneven fineness distribution. On the other hand, a stretching temperature of 150° C. or less is preferable because the fiber can slip smoothly on the stretching rollers to ensure depression of thread breakage and stable stretching. The stretching temperature is more preferably 60 to 140° C. and still more preferably 70 to 130° C. In addition, heat setting may be performed at 50 to 150° C. as required.
If stretching is to be performed, the stretching speed may be set appropriately to suit the type and content ratio of the thermoplastic resin and the stretching method which may be of the two step type or the direct spinning and stretching type, but it is preferably 30 to 1,000 m/min. A stretching speed of 30 m/min or more is preferable because the traveling of the thread is maintained stable and thread breakage is depressed. On the other hand, a stretching speed of 1,000 m/min or less is preferable because thread breakage during stretching is depressed to ensure stable stretching. The stretching speed is more preferably 50 to 800 m/min and still more preferably 100 to 500 m/min.
There are no specific limitations on the method to be used for the dissolving-out of the island component for the present invention, and the island component may be dissolved out from either unstretched yarns or stretched yarns of polymethylpentene conjugate fiber having a sea-island structure, or the island component may be dissolved out after polymethylpentene conjugate fiber of a sea-island structure is processed into a fiber structure of woven or knitted fabrics, nonwoven fabrics, or spun yarns. Alternatively, the island component may not be dissolved out completely, but part of the island component may be left in the porous polymethylpentene fiber. Leaving part of the thermoplastic resin of the island component is preferable because colors can be imparted to the porous polymethylpentene fiber by dyeing the thermoplastic resin.
For the present invention, a solvent used for dissolving out the island component may be selected appropriately to suit the type, copolymerization component, and copolymerization ratio of the thermoplastic resin. For example, useful ones include, but not limited to, aqueous alkali solutions containing alkali metal compounds such as sodium hydroxide, potassium hydroxide, sodium carbonate, and potassium carbonate when polyester is used as thermoplastic resin; aqueous acid solutions containing formic acid when polyamide is used; hot water when polyvinyl alcohol or polyalkylene glycol is used; organic solvents such as toluene, xylene, and trichloroethylene when polyolefin or polystyrene is used; and water and organic solvents such as acetone and chloroform when cellulose derivatives are used.
The treatment temperature and treatment time for dissolving out the island component may be set appropriately to suit the type of the thermoplastic resin, the content ratio between the sea component and the island component, and the solvent used for dissolving out the island component. Furthermore, the content of the thermoplastic resin left in the porous polymethylpentene fiber can be controlled by adjusting the treatment temperature and treatment time for dissolving out the island component. Here, the content of the remaining thermoplastic resin can be set appropriately to suit the specific gravity, color developing property, content ratio, etc., of the thermoplastic resin, but it is preferably 1 to 20%. If the content of the remaining thermoplastic resin is 1% or more, it is preferable because colors can be imparted to the porous polymethylpentene fiber. If the content of the remaining thermoplastic resin is 20% or less, it is preferable because it can ensure both lightness attributable to the polymethylpentene resin and color developing property of the thermoplastic resin. The content of the remaining thermoplastic resin is more preferably 3 to 17% and still more preferably 5 to 15%.
The concentration of the solvent, such as aqueous alkali solution and aqueous acid solution, used for dissolving out the island component may be set appropriately to suit the type of the thermoplastic resin, copolymerization component thereof, copolymerization ratio thereof, content ratio between the sea component and the island component, and treatment temperature and treatment time for dissolving out the island component. Furthermore, the content of the thermoplastic resin left in the porous polymethylpentene fiber can be controlled by adjusting the concentration of the solvent, such as aqueous alkali solution and aqueous acid solution, used for dissolving out the island component.
For the present invention, an accelerator may be added as required to the solvent used for dissolving out the island component with the aim of promoting the dissolving-out of the island component. An accelerator may be selected appropriately to suit the type of the thermoplastic resin used, copolymerization component thereof, copolymerization ratio thereof, content ratio between the sea component and the island component, and treatment temperature and treatment time for dissolving out the island component. When polyester is used as the thermoplastic resin, for example, specific examples of useful accelerators include, but not limited to, quaternary ammonium salts such as octyl dimethyl ammonium chloride, lauryl trimethyl ammonium chloride, trimethyl benzyl ammonium chloride, lauryl dimethyl benzyl ammonium chloride, stearyl trimethyl ammonium chloride, cetyl trimethyl ammonium chloride, octyl trimethyl ammonium bromide, lauryl dibutyl allyl ammonium bromide, cetyl dimethyl cyclohexyl ammonium bromide, lauryl phenyl trimethyl ammonium methosulfate, stearyl ethyl dihydro oxyethyl ammonium ethosulfate, and lauryl trihydroxyethyl ammonium hydroxide. These accelerators may be used singly, or a plurality thereof may be used in combination.
For the dissolving-out of the island component, a suitable apparatus may be selected appropriately to suit the polymethylpentene conjugate fiber or the fiber structure of polymethylpentene conjugate fiber. Specific examples of apparatuses useful for dissolving out the island component include, but not limited to, those commonly used for dyeing processing such as cheese dyeing machine, jet dyeing machine, drum dyeing machine, beam dyeing machine, wince dyeing machine, jigger dyeing machine, and high pressure jigger dyeing machine, as well as those equipped with a pad designed to feed a solvent for dissolving out the island component prior to atmospheric pressure steam treatment, compression steam treatment, or dry heat treatment.
For the present invention, the dissolving-out of the island component may be followed by treatment such as rinsing, neutralization, and drying that suits the type of the thermoplastic resin and the type of the solvent used for dissolving out the island component.
For the present invention, dyeing may be performed as required for any of the following states: polymethylpentene conjugate fiber, fiber structure formed of polymethylpentene conjugate fiber, porous polymethylpentene fiber, and fiber structure formed of porous polymethylpentene fiber. Alternatively, the thermoplastic resin of the island component may not be dissolved out completely, but part of the thermoplastic resin of the island component may be left in the porous polymethylpentene fiber when it is dyed.
There are no specific limitations on the dyeing method to be used for the present invention, and generally known methods may be performed favorably using a cheese dyeing machine, jet dyeing machine, drum dyeing machine, beam dyeing machine, jigger dyeing machine, high pressure jigger dyeing machine, etc.
For the present invention, a suitable dye selected appropriately to suit the type of the thermoplastic resin. Almost any dye cannot effectively dye the polymethylpentene based resin contained in the polymethylpentene conjugate fiber or porous polymethylpentene fiber, but fiber or fiber structures with good color developing property can be obtained by dyeing the thermoplastic resin. The dyes that can be adopted favorably include, but not limited to, disperse dyes for polyester used as thermoplastic resin; acidic dyes for polyamide; cationic dyes for thermoplastic polyacrylonitrile; acidic dyes for thermoplastic polyurethane; cationic dyes for modified polyolefin; disperse dyes for polyvinyl chloride; and disperse dyes for cellulose derivatives.
For the present invention, there are no specific limitations on the dye concentration and dyeing temperature, and generally known methods can be adopted favorably. In addition, degumming may be performed as required before the dyeing step and reduction cleaning may be performed after the dyeing step.
In the polymethylpentene conjugate fiber and fiber structures formed of the polymethylpentene conjugate fiber that are produced according to the present invention, deep, vivid colors have been imparted to the lightweight polymethylpentene fiber. Accordingly, they can be applied to apparel and other products that require lightness and color developing property, in addition to those uses where conventional polyolefin based fibers have been adopted. Furthermore, the porous polymethylpentene fiber and fiber structures formed of the porous polymethylpentene fiber that are produced according to the present invention not only have excellent lightweight property, but also contain pores with uniformity diameters, leading to a high pore resistance to external force. Accordingly, they can be applied favorably to uses that require lightness, heat insulation, and cushioning properties. Porous polymethylpentene fiber that contains thermoplastic resin can be applied favorably to uses that require color developing property because colors can be imparted thereto. The uses where conventional polyolefin based fibers have been adopted include, but not limited to, interior uses such as tile carpets, household carpets, automobile mats and general material uses such as ropes, protective nets, filter fabrics, narrow tapes, braids, and chair upholstery. In addition, there will be new uses to be developed by the present invention, including, but not limited to, general clothing such as women's wear, men's wear, lining, underwear, down jackets, vests, inner garments, and outer garments; sports clothing such as wind breakers, outdoor sports wear, skiing wear, golf wear, and swimsuits; bedding such as mattress wadding, outer fabrics of mattress, mattress covers, blankets, outer fabrics of blankets, blanket covers, pillow wadding, pillow covers, and sheets; interior materials such as tablecloth and curtains; and other materials such as belts, bags, sewing threads, sleeping bags, and tents.
EXAMPLES
The invention is described in more detail below with reference to Examples. The characteristic values given in Examples were determined by the following methods.
A. Melting Point
In regard to the polymethylpentene based resin and thermoplastic resin, the melting point was measured using a model DSC7 differential scanning calorimeter (DSC) manufactured by Perkin-Elmer. A specimen of about 10 mg was heated from 30° C. to 280° C. in a nitrogen atmosphere at a heating rate of 15° C./min and maintained at 280° C. for 3 minutes to remove heat history from the specimen. Then, it was cooled from 280° C. to 30° C. at a cooling rate of 15° C./min and maintained at 30° C. for 3 minutes. It was heated again from 30° C. to 280° C. at a heating rate 15° C./min, and the peak temperature of the endothermic peak observed during the second heating process was assumed to be its melting point (° C.). Here, three measurements were made for a specimen, and their average was taken as the melting point.
B. Sea-Island/Compatibilizer Content Ratio
The sea-island/compatibilizer content ratio (by weight) was calculated from the weight of the sea component, weight of the island component, and weight the compatibilizer (in the case where a compatibilizer was used) adopted to produce polymethylpentene conjugate fiber.
C. Melt Viscosity Ratio
Polymethylpentene based resin (a) and thermoplastic resin (b) were vacuum-dried first and left to stand in a nitrogen atmosphere for 5 minutes, and measurements were made using Capilograph 1B (manufactured by Toyo Seiki Co., Ltd.) and a capillary with a hole size of 1.0 mm and hole length of 10 mm. Here, measurements was made at the same temperature as the spinning temperature described in each Example given below, and the apparent viscosity (Pa·s) at a shear velocity of 1216 sec −1 was assumed to represent the melt viscosity (Pa·s). Here, three measurements were made for a specimen, and their average was taken as the melt viscosity. The melt viscosity ratio was calculated by the following equation, where ηa and ηb show the melt viscosity of polymethylpentene based resin (a) and that of thermoplastic resin (b), respectively:
melt viscosity ratio (η b/ηa )=η b/ηa
D. Fineness
In an environment with a temperature of 20° C. and a humidity of 65% RH, a 100 m fiber specimen taken from the polymethylpentene conjugate fiber (before dissolving out the island component) or porous polymethylpentene fiber (after dissolving out the island component) prepared in each Example was wound into a hank using an electric sizing reel manufactured by INTEC. The weight of the resulting hank was measured and its fineness (dtex) was calculated by the following equation. Here, five measurements were made for a specimen, and their average was taken as its fineness.
fineness (dtex)=weight (g) of fiber (100 m)×100
E. Strength and Elongation Percentage
The strength and elongation percentage of specimens of the polymethylpentene conjugate fiber (before dissolving out the island component) or porous polymethylpentene fiber (after dissolving out the island component) prepared in each Example were calculated according to 8.5 of JIS L 1013 (1999) (Test method for chemical fiber filament yarn). In an environment with a temperature of 20° C. and a humidity of 65% RH, a tensile test was performed using Autograph AG-50NISMS (manufactured by Shimadzu Corporation) under the conditions of an initial specimen length of 20 cm and tension speed of 20 cm/min. The strength (cN/dtex) was calculated by dividing the stress (cN) at the point showing the maximum load by the fineness (dtex) and the elongation percentage (%) was calculated by the following equation from the elongation (L1) at the point showing the maximum load and the initial specimen length (L0). Here, ten measurements were made for a specimen, and their average was taken as its strength and elongation percentage.
elongation percentage (%)={( L 1 −L 0)/ L 0}×100
F. Initial Tensile Resistance
The initial tensile resistance of a specimen of the polymethylpentene conjugate fiber (before dissolving out the island component) or porous polymethylpentene fiber (after dissolving out the island component) prepared in each Example was calculated according to 8.10 of JIS L 1013 (1999) (Test method for chemical fiber filament yarn). Measurements were made as in the above paragraph E and a load-elongation curve was drawn. In the vicinity of the origin, a maximum in the load-stretch curve was determined and the initial tensile resistance (cN/dtex) was calculated by the equation described in 8.10 of JIS L 1013 (1999) (Test method for chemical fiber filament yarn). Here, five measurements were made for a specimen, and their average was taken as its initial tensile resistance.
G. Content of Remaining Thermoplastic Resin (%)
The porous polymethylpentene fiber (after dissolving out the island component) prepared in each Example was circular-knitted to provide a specimen and its weight W0 (g) was measured after drying at 60° C. for 2 hours in a drier. Subsequently, the specimen was immersed in a solvent under the same conditions as in each Example, rinsed, and dried at 60° C. for 2 hours in a drier, followed by measuring its weight W1 (g). The steps of immersion in the solvent, rinsing, and drying were performed repeatedly until the specimen no longer showed changes in weight. The weight W2 (g) was determined at the point where the specimen no longer showed changes in weight and the content (%) of the remaining thermoplastic resin was calculated by the following equation:
content of remaining thermoplastic resin (%)={( W 1− W 2)/ W 0}×100
H. Average Fiber Diameter, Dispersion Diameter of Island Domains, Average Diameter of Pores
Platinum-palladium alloy was deposited on the polymethylpentene conjugate fiber (before dissolving out the island component) or porous polymethylpentene fiber (after dissolving out the island component) prepared in each Example and the cross section perpendicular to the fiber axis, i.e. the fiber cross section, was observed using a S-4000 scanning electron microscope (SEM) manufactured by Hitachi, Ltd., followed by taking a microphotograph of the fiber cross section. To determine the average fiber diameter, 30 fibers taken at random were observed at a magnification of 300× and their diameters were measured and averaged to calculate the average fiber diameter (μm). To determine the dispersion diameter of the island domains and the average diameter of the pores, observation was performed at a magnification of 300×, 500×, 1,000×, 3,000×, 5,000×, 10,000×, 30,000×, or 50,000× and microphotographs were taken at the lowest magnification that could give a view containing 100 or more island domains or pores. In regard to the photographs thus taken, the diameter was measured for 100 island domains or pores selected randomly from each photograph and the average of the measurements was taken as the dispersion diameter (μm) of the island domains or the average diameter (μm) of the pores. The island domains and pores existing in a fiber cross section did not necessarily have a perfect circular shape. For each of those of a non-perfect circle, its area was measured and converted into the diameter of a perfect circle, which was adopted as the dispersion diameter of the island domain or the diameter of the pore.
When the fiber cross section of a single yarn did not contain as many as 100 island domains or pores, a plurality of single yarns produced under the same conditions were used as specimens for fiber cross section observation. When taking a microphotograph, photographing was performed at the highest magnification at which the entire single yarn could be observed. For the photographs thus taken, the dispersion diameter of the island domains or the average diameter of the pores in the fiber cross section of each single yarn were measured and the average of the 100 measurements of the dispersion diameter of island domains or the diameter of pores was taken to represent the dispersion diameter of the island domains or the diameter of the pores.
I. Coefficient of Variation CV of Dispersion Diameter of Island Domains or Diameter of Pores
First, the standard deviation (σ ALL ) and the average (D ALL ) were calculated for the dispersion diameter of 100 island domains or the diameter of 100 pores measured in the above paragraph H, and then the coefficient of variation CV(%) of the dispersion diameter of the island domains or the diameter of the pores were calculated by the following equation:
coefficient of variation CV(%)=(σ ALL /D ALL )×100
J. Specific Gravity
The specific gravity of a specimen of the polymethylpentene conjugate fiber (before dissolving out the island component) prepared in each Example was calculated according to 8.17 (Sink-float method) of JIS L 1013 (1999) (Test method for chemical fiber filament yarn). A specific gravity measuring liquid was prepared using water as heavy liquid and ethyl alcohol as light liquid. In a temperature controlled bath of a temperature of 20±0.1° C., a fiber specimen of about 0.1 g was left in the specific gravity measuring liquid for 30 minutes and then the sink-and-float state of the specimen was observed. Either the heavy liquid or the light liquid was added depending on the sink-and-float state and the specimen was left to stand for additional 30 minutes. After confirming that the specimen was in an equilibrium sink-and-float state, the specific gravity of the specific gravity measuring liquid was measured and then the specific gravity of the specimen was calculated. Here, five measurements were made for a specimen, and their average was taken as its specific gravity.
K. Porosity and Specific Gravity
The porosity (%) and apparent density (g/cm 3 ) of the porous polymethylpentene fiber (after dissolving out the island component) prepared in each Example were measured by mercury intrusion porosimetry using an Autopore IV9510 porosimeter manufactured by Shimadzu Corporation. For the present invention, the apparent density is referred to as specific gravity. Here, three measurements were made for a specimen, and their average was taken as its porosity or specific gravity.
L. Specific Gravity Increase Rate
The porous polymethylpentene fiber (after dissolving out the island component) prepared in each Example was twisted 1,500 turns/m and then untwisted, followed by calculating the specific gravity as in the above paragraph K. The specific gravity increase rate was calculated by the following equation from the specific gravity Ha before the twisting and the specific gravity Hb after the twisting:
specific gravity increase rate (%)={( Hb−Ha )/ Ha}× 100
M. L* Value
The polymethylpentene conjugate fiber (before dissolving out the island component) or porous polymethylpentene fiber (after dissolving out the island component) prepared in each Example was circular-knitted to prepare a specimen, which was degummed at 70° C. for 20 minutes and subjected to dry heat setting at 160° C. for 2 minutes, followed by dyeing by an ordinary method. The L* value of the dyed specimen was measured using a CM-3700d spectrophotometer (manufactured by Minolta) with a D65 light source and view angle of 10° under SCE (specular component excluded) optical conditions. Here, three measurements were made for a specimen, and their average was taken as its L* value. The dyeing methods that were used for different fibers are as described below.
When polyethylene terephthalate (PET), polypropylene terephthalate (PPT), polylactic acid (PLA), cellulose diacetate (CDA), or cellulose acetate propionate (CAP) was used as thermoplastic resin, Kayalon Polyester Black EX-SF200, a disperse dye manufactured by Nippon Kayaku Co., Ltd., was adopted to dye it. A circular-knitted specimen was dyed with a dye solution containing 4 wt % of the dye and adjusted to pH 5.0 under the conditions of a bath ratio of 1:100 and a dyeing time of 60 minutes. Here, the dyeing temperature was 100° C. for PET and 130° C. for PPT, PLA, CDA, and CAP.
When nylon 6 (N6) or nylon 66 (N66) was used as thermoplastic resin, Kayanol Milling Black TLB, an acidic dye manufactured by Nippon Kayaku Co., Ltd., was adopted to dye it. A circular-knitted specimen was dyed with a dye solution containing 8 wt % of the dye and adjusted to pH 4.5 under the conditions of a bath ratio of 1:100, dyeing temperature of 100° C., and a dyeing time of 60 minutes.
When polymethyl methacrylate (PMMA) or maleic anhydride modified polypropylene (MPP) was used as thermoplastic resin, Kayacryl Black YA, a cationic dye manufactured by Nippon Kayaku Co., Ltd., was adopted to dye it. A circular-knitted specimen was dyed with a dye solution containing 8 wt % of the dye and adjusted to pH 4.0 under the conditions of a bath ratio of 1:100, dyeing temperature of 100° C., and a dyeing time of 60 minutes.
N. Lightweight Property
For the polymethylpentene conjugate fiber (before dissolving out the island component) prepared in each Example, lightweight property was evaluated based on the specific gravity of the fiber calculated in the above paragraph J and ranked according to a four level criterion. Results are shown as ⊚, ∘, Δ, or x. To show the evaluation results, ⊚ represents the highest quality level, and ∘, Δ, and x represent lower, still lower, and the lowest quality levels, respectively. A specimen was ranked as ⊚ when the specific gravity of the fiber was less than 1.0, ∘ when it was 1.0 or more and less than 1.1, Δ when it was 1.1 or more and less than 1.2, and x when it was 1.2 or more, and judged as acceptable when it was ranked as ∘ (1.0 or more and less than 1.1) or higher. For the porous polymethylpentene fiber (after dissolving out the island component) prepared in each Example, lightweight property was evaluated based on the specific gravity of the fiber as calculated in the above paragraph K and ranked according to a four level criterion. Results are shown as ⊚, ∘, Δ, or x. To show the evaluation results, ⊚ represents the highest quality level, and ∘, Δ, and x represent lower, still lower, and the lowest quality levels, respectively. A specimen was ranked as ⊚ when the specific gravity of the fiber was 0.7 or less, ∘ when it was more than 0.7 and 0.8 or less, and x when it was more than 0.8, and judged as acceptable when it was ranked as ⊚ or ∘.
O. Resistance of Hollows
For the porous polymethylpentene fiber (after dissolving out the island component) prepared in each Example, hollow resistance was evaluated based on the specific gravity increase rate as calculated in the above paragraph L and ranked according to a four level criterion. Results are shown as ⊚, ∘, Δ, or x. To show the evaluation results, ⊚ represents the highest quality level, and ∘, Δ, and x represent lower, still lower, and the lowest quality levels, respectively. A specimen was ranked as ⊚ when the specific gravity increase rate was less than 5%, ∘ when it was 5% or more and less than 10%, and x when it was 10% or more, and judged as acceptable when it was ranked as ⊚ or ∘.
P. Color Developing Property
The color developing property was evaluated based on the L* value of a circular-knitted specimen dyed as in the above paragraph M and ranked according to a four level criterion. Results are shown as ⊚, ∘, Δ, or x. To show the evaluation results, ⊚ represents the highest quality level, and ∘, Δ, and x represent lower, still lower, and the lowest quality levels, respectively. A specimen was evaluated as ⊚ when the L* value was less than 40, ∘ when it was 40 or more and less than 50, Δ when it was 50 or more and less than 60, and x when it was 60 or more, and judged as acceptable when it was ranked as ∘ (40 or more and less than 50) or higher.
Q. Washing Fastness
Washing fastness evaluation was carried out according to A-2 of JIS L 0844 (2004) (Test method for color fastness to washing). Using a Laundermeter tester manufactured by Daiei Kagaku Seiki Mfg. Co., Ltd., a circular-knitted specimen dyed as in the above paragraph M was subjected to laundering treatment along with a piece of white cloth attached to the tester, and the degree of discoloration of the specimen was determined with reference to a discoloration gray scale as specified in JIS L 0804 (2004). The washing fastness was evaluated in terms of the degree of stain on the attached white cloth determined with reference to a stain gray scale as specified in JIS L 0805 (2005). Here, the washing fastness is evaluated as classes 1 to 5 in 0.5 increments, with classes 5 and 1 representing the highest and lowest quality levels, respectively. The washing fastness was indicated by ⊚ for class 4 or higher and lower than class 5, ∘ for class 3 or higher and lower than class 4, Δ for class 2 or higher and lower than class 3, or x for lower than class 2, and the specimen was judged as acceptable when it was ranked as ∘ (class 3 or higher and lower than class 4) or higher.
R. Rubbing Fastness
Rubbing fastness evaluation was carried out according to 7.1 of JIS L 0849 (2004) (Test method for color fastness to rubbing). Using a Gakushin-Type Rubbing Tester RT-200 manufactured by Daiei Kagaku Seiki Mfg. Co., Ltd., a circular-knitted specimen dyed as in the above paragraph M was rubbed with white cotton cloth (Kanakin No. 3), and its rubbing fastness was evaluated based on the degree of stain on the white cotton cloth determined with reference to a stain gray scale as specified in JIS L 0805 (2005). Here, the rubbing fastness is evaluated as classes 1 to 5 in 0.5 increments, with classes 5 and 1 representing the highest and lowest quality levels, respectively. The rubbing fastness was indicated by ⊚ for class 4 or higher and lower than class 5, ∘ for class 3 or higher and lower than class 4, Δ for class 2 or higher and lower than class 3, or x for lower than class 2, and the specimen was judged as acceptable when it was ranked as ∘ (class 3 or higher and lower than class 4) or higher.
S. Light Fastness
Light fastness evaluation was carried out according to JIS L 0842 (2004) (Test method for color fastness to ultraviolet light of carbon-arc lamp). Using an Ultraviolet Auto Fade Meter U48AU manufactured by Suga Test Instrument Co., Ltd., a circular-knitted specimen dyed as in the above paragraph I was exposed to light from a carbon-arc lamp, and its light fastness was evaluated based on the degree of discoloration of the specimen determined with reference to a discoloration gray scale as specified in JIS L 0804 (2004). Here, the light fastness is evaluated as classes 1 to 5 in 0.5 increments, with classes 5 and 1 representing the highest and lowest quality levels, respectively. The light fastness was indicated by ⊚ for class 4 or higher and lower than class 5, ∘ for class 3 or higher and lower than class 4, Δ for class 2 or higher and lower than class 3, or x for lower than class 2, and the specimen was judged as acceptable when it was ranked as ∘ (class 3 or higher and lower than class 4) or higher.
T. Levelness of Dyeing
The porous polymethylpentene fiber prepared in each Example was dyed by the same method as in the above paragraph M and subjected to observation of a section perpendicular to the fiber axis, i.e. fiber cross section, using a VHX-8500 microscope manufactured by Keyence Corporation. The levelness of dyeing was evaluated according to a four level criterion (represented as ⊚, ∘, Δ, or x) based on the stained state of the fiber cross section. To show the evaluation results, ⊚ represents the highest quality level, and ∘, Δ, and x represent lower, still lower, and the lowest quality levels, respectively. A specimen was ranked as ⊚ when the fiber cross section was found dyed uniformly, ∘ when the fiber cross section was found dyed nearly uniformly, Δ when the fiber cross section was found dyed slightly, and x when the fiber cross section was found little dyed. When the specimen was ranked as ∘ (the fiber cross section as found dyed nearly uniformly) or higher, it was judged as acceptable with vivid color developed from the interior of the fiber (o) or acceptable with excellent vivid color developed from the interior of the fiber (⊚).
U. Dyeing Specks
Circular-knitted specimens dyed as in the above paragraph M were evaluated according to a four level criterion (represented as ⊚, ∘, Δ, and x) based on a consultation by five examiners having 5-year or longer experience in quality evaluation. To show the evaluation results, ⊚ represents the highest quality level, and ∘, Δ, and x represent lower, still lower, and the lowest quality levels, respectively. A specimen was ranked as ⊚ when it was found dyed highly uniformly with no dyeing specks detected, ∘ when it was found dyed nearly uniformly with almost no dyeing specks detected, Δ when it was found dyed little uniformly with slight dyeing specks detected, and x when it was found not dyed uniformly with clear dyeing specks detected. The specimen was judged as acceptable when it was ranked as ∘ (the fiber cross section was found dyed nearly uniformly with almost no dyeing specks detected) or higher.
Example 1
Using a twin screw extruder, 80 wt % of polymethylpentene (PMP) (DX820, manufactured by Mitsui Chemicals, Inc., melting point 232° C., MFR 180 g/10 min) used as sea component and 20 wt % of polylactic acid (PLA) (melting point 168° C., weight average molecular weight 145,000) used as island component were kneaded at a kneading temperature of 260° C. The strand discharged from the twin screw extruder was cooled in water and then cut by a pelletizer at intervals of about 5 mm to provide pellets. Here, the melt viscosity ratio between the sea component and the island component was 1.7. The pellets obtained were vacuum-dried at 95° C. for 12 hours and supplied to an extruder type melt spinning machine in which they were melted and discharged through a spinning nozzle (discharge hole size 0.3 mm, discharge hole length 0.6 mm, number of holes 36, round holes) at a spinning temperature 260° C. to provide spun threads. These spun threads were cooled in a cooling air flow with an air temperature of 20° C. and flow speed of 25 m/min, collected while supplying oil from an oil feeder, taken up by a first godet roller rotating at 1,000 m/min, wound up by a winder via a second godet roller rotating at the same speed as the first godet roller to provide an unstretched yarn of 180 dtex-36f. The unstretched yarn obtained was stretched under the conditions of a first hot roller temperature of 90° C., second hot roller temperature of 130° C., and draw ratio of 1.8 to provide a stretched yarn of 100 dtex-36f. Using a circular knitting machine, a circular-knitted fabric was prepared from the resulting stretched yarn of polymethylpentene conjugate fiber, and it was then degummed, subjected to dry heat setting, and dyed by the aforementioned methods.
Table 1 shows evaluation results on fiber characteristics of the resulting polymethylpentene conjugate fiber and characteristics of the circular-knitted fabric of the polymethylpentene conjugate fiber. The polymethylpentene conjugate fiber obtained had a specific gravity of 0.92 and accordingly had very good lightweight property. Furthermore, polylactic acid with good color developing property was found to form island domains that were finely dispersed in a sea domain of polymethylpentene with a low refractive index, resulting in a fabric specimen entirely dyed vividly and uniformly, indicating an excellent color developing property. Furthermore, it had acceptable level of fastness to washing, rubbing, and light.
Example 2
Except for using polymethylpentene (PMP) (RT18, manufactured by Mitsui Chemicals, Inc., melting point 232° C., MFR 26 g/10 min) as sea component, polymethylpentene conjugate fiber and circular-knitted fabric were prepared in the same way as in Example 1, and it was degummed, subjected to dry heat setting, and dyed. Here, the melt viscosity ratio between the sea component and the island component was 1.1.
Table 1 shows evaluation results on fiber characteristics of the resulting polymethylpentene conjugate fiber and fabric characteristics of the circular-knitted fabric of the polymethylpentene conjugate fiber. The melt viscosity ratio between the sea component and the island component is low and the dispersion diameter of the island domains is small, resulting in a low L* value and development of deep, vivid colors. It also had excellent lightweight property and had acceptable level of fastness to washing, rubbing, and light.
Examples 3 to 5
Except for changing the content ratio between the sea component and the island component as shown in Table 1, polymethylpentene conjugate fiber and circular-knitted fabric were prepared in the same way as in Example 1, and it was degummed, subjected to dry heat setting, and dyed.
Table 1 shows evaluation results on fiber characteristics of the resulting polymethylpentene conjugate fiber and fabric characteristics of the circular-knitted fabric of the polymethylpentene conjugate fiber. In Example 3, the fabric had good lightweight property though slightly high in specific gravity due to a larger proportion of polylactic acid and had acceptable level of fastness to washing, rubbing, and light though slightly lower than the above. Its color developing property was excellent. In Example 4, the fabric had good lightweight property and color developing property and also gave acceptable results in the various fastness tests, thus proving excellent fabric characteristics. In Example 5, the entire fabric specimen was found dyed vividly and uniformly though slightly high in L* value due to a smaller proportion of polylactic acid, and the fabric was also acceptable in other fabric characteristics.
Examples 6 and 7
The sea component of polymethylpentene (PMP) (DX820, manufactured by Mitsui Chemicals, Inc., melting point 232° C., MFR 180 g/10 min) and the island component of polylactic acid (PLA) (melting point 168° C., weight average molecular weight 145,000) were vacuum-dried at 95° C. for 12 hours, and then 80 wt % of the sea component and 20 wt % of the island component were supplied to a pressure melter type conjugate spinning machine, in which they were melted separately and discharged at a spinning temperature of 260° C. through a spinning nozzle designed for sea-island conjugate fiber production (discharge hole size 0.3 mm, discharge hole length 0.6 mm, number of holes 36, round holes) to provide spun threads. The spinning nozzle designed for sea-island conjugate fiber production used in Example 6 was configured for eight island domains and that used in Example 7 was configured for 32 island domains. These spun threads were cooled in a cooling air flow with an air temperature of 20° C. and flow speed of 25 m/min, collected while supplying oil from an oil feeder, taken up by a first godet roller rotating at 1,000 m/min, wound up by a winder via a second godet roller rotating at the same speed as the first godet roller to provide an unstretched yarn of 180 dtex-36f. The unstretched yarn obtained was stretched under the conditions of a first hot roller temperature of 90° C., second hot roller temperature of 130° C., and draw ratio of 1.8 to provide a stretched yarn of 100 dtex-36f. Using a circular knitting machine, a circular-knitted fabric was prepared from the resulting stretched yarn of polymethylpentene conjugate fiber, and it was then degummed, subjected to dry heat setting, and dyed by the aforementioned methods.
Table 1 shows evaluation results on fiber characteristics of the resulting polymethylpentene conjugate fiber and characteristics of the circular-knitted fabric of the polymethylpentene conjugate fiber. In Example 6, the number of island domains was 8 and the possibility that light passing through the sea domain reaches dyed island domains was slightly lower, leading to a slightly higher L* value, but the entire fabric specimen was dyed vividly and uniformly, proving good color developing property. Furthermore, the fabric gave excellent results in the lightweight property and various fastness tests. In Example 7, the number of island domains was 32 and transmitted light toward dyed island domains and reflected light from island domains were mixed randomly to give a lower L* value and deep, vivid colors. The fabric was also acceptable in other fabric characteristics. In Examples 6 and 7, island domains of polylactic acid with good color developing property were finely dispersed in a sea domain of polymethylpentene with a low refractive index, making it possible to provide polymethylpentene conjugate fiber with excellent color developing property.
Example 8
Except for adding 5 wt % (as outer percentage) of aminomodified styrene-ethylene-butylene-styrene copolymer (SEBS) (Dynalon 8630P, manufactured by JSR Corporation) as compatibilizer, the same procedure as in Example 1 was carried out to produce polymethylpentene conjugate fiber and a circular-knitted fabric specimen, followed by degumming, dry heat setting, and dyeing. Here, PMP, PLA, and SEBS had a content ratio (by weight) of 80/20/5, which is equivalent to 76.2/19.0/4.8 in percentage of the total weight (100) of PMP, PLA, and SEBS.
Table 1 shows evaluation results on fiber characteristics of the resulting polymethylpentene conjugate fiber and fabric characteristics of the circular-knitted fabric of the polymethylpentene conjugate fiber. The addition of the compatibilizer worked to improve the compatibility between polymethylpentene and polylactic acid to decrease the dispersion diameter of the island component and lower the L* value, resulting in excellent deep, vivid color developing property. The fabric also had excellent lightweight properties and had acceptable quality in terms of fastness to washing, rubbing, and light.
Examples 9 to 16
The island component was changed from polylactic acid to other thermoplastic resins as shown in Table 2. The thermoplastic resins used were polyethylene terephthalate (PET) (T701T, manufactured by Toray Industries, Inc., melting point 257° C.) in Example 9, polypropylene terephthalate (PPT) (Corterra CP513,000, manufactured by Shell, melting point 225° C.) in Example 10, nylon 6 (N6) (Amilan CM1017, manufactured by Toray Industries, Inc., melting point 225° C.) in Example 11, nylon 66 (N66) (CM3001-N, manufactured by Toray Industries, Inc., melting point 265° C.) in Example 12, polymethyl methacrylate (PMMA) (Acrypet VH000, manufactured by Mitsubishi Rayon Co., Ltd., melting point 140° C.) in Example 13, maleic anhydride modified polypropylene (MPP) (Yumex 1010, manufactured by Sanyo Chemical Industries Ltd., melting point 142° C.) in Example 14, cellulose acetate propionate (CAP) (CAP-482-20, manufactured by Eastman Chemical Company, melting point 195° C.) in Example 15, and cellulose diacetate (CDA) (Acety, manufactured by Daicel, containing 22% diethyl phthalate, melting point 160° C.) in Example 16. For polymethylpentene, RT18 manufactured by Mitsui Chemicals, Inc., was used in Examples 9 and 11 to 13 and DX820 manufactured by Mitsui Chemicals, Inc., was used in Examples 10 and 14 to 16. The spinning temperature was 290° C. in Examples 9 and 12, 260° C. in Examples 10, 11, 13, and 14, and 240° C. in Examples 15 and 16. The other conditions were the same as in Example 1 for preparing polymethylpentene conjugate fiber and a circular-knitted fabric specimen, followed by degumming, dry heat setting, and dyeing. Here, the melt viscosity ratio between the sea component and the island component was as shown in Table 2.
Table 2 shows evaluation results on fiber characteristics of the resulting polymethylpentene conjugate fiber and fabric characteristics of the circular-knitted fabric of the polymethylpentene conjugate fiber. Though some thermoplastic resins gave specimens with slightly lower color developing property and fastness to light, all thermoplastic resins gave specimens containing island domains finely dispersed in a sea domain and having good color developing property and acceptable quality in terms of lightness and fastness to washing, rubbing, and light.
Comparative Example 1
Except for adding no island component and using polymethylpentene as monocomponent, the same procedure as in Example 1 was carried out to produce polymethylpentene fiber and a circular-knitted fabric specimen, followed by degumming, dry heat setting, and dyeing. Here, the same disperse dye as in Example 1 was used for dyeing.
Table 3 shows evaluation results on fiber characteristics of the resulting polymethylpentene fiber and fabric characteristics of the circular-knitted fabric of the polymethylpentene fiber. Since polymethylpentene has no polar functional group, it cannot be dyed effectively with a dye, resulting in poor color developing property.
Comparative Examples 2-4
Except for using spinning nozzle designed for core-sheath conjugate fiber production (discharge hole size 0.3 mm, discharge hole length 0.6 mm, number of holes 36, round holes) and adopting the content ratios between the core component and the sheath component shown in Table 3, the same procedure as in Example 6 was carried out to produce polymethylpentene conjugate fiber and a circular-knitted fabric specimen, followed by degumming, dry heat setting, and dyeing It should be noted that the sea component corresponds to the sheath component while the island component corresponds to the core component in Comparative examples 2 to 4.
Table 3 shows evaluation results on fiber characteristics of the resulting polymethylpentene conjugate fiber and characteristics of the circular-knitted fabric of the polymethylpentene conjugate fiber. In Comparative example 2, although the polylactic acid of the core component was dyed well, it is covered with the polymethylpentene of the sheath component, leading to a high L* value and failing to give deep, vivid colors. In Comparative examples 3 and 4, although the content ratio was changed to increase the content of polylactic acid, the color developing property was not improved, leading to fabric specimens with inferior color developing property. When core-sheath type conjugate fiber was prepared as in Comparative examples 2 to 4, transmitted light toward dyed island domains and reflected light from island domains were not mixed randomly, failing to impart color developing property to the polymethylpentene based resin.
Comparative Example 5
Using a twin screw extruder, 80 wt % of high density polyethylene (HDPE) (HI-ZEX 2200J, manufactured by Prime Polymer Co., Ltd., melting point 135° C.) used as sea component and 20 wt % ethylene-vinyl acetate copolymer (EVA) (Evaflex EV150, manufactured by Dupont Mitsui, melting point 61° C.) used as island component were kneaded at a kneading temperature 155° C. The strand discharged from the twin screw extruder was cooled in water and then cut by a pelletizer at intervals of about 5 mm to provide pellets. Here, the melt viscosity ratio between the sea component and the island component was 2.8. The pellets obtained were vacuum-dried at 95° C. for 12 hours and supplied to an extruder type melt spinning machine in which they were melted and discharged through a spinning nozzle (discharge hole size 0.3 mm, discharge hole length 0.6 mm, number of holes 36, round holes) at a spinning temperature 155° C. to provide spun threads. These spun threads were cooled in a cooling air flow with an air temperature of 20° C. and flow speed of 25 m/min, collected while supplying oil from an oil feeder, taken up by a first godet roller rotating at 250 m/min, wound up by a winder via a second godet roller rotating at the same speed as the first godet roller to provide an unstretched yarn of 100 dtex-36f. Using a circular knitting machine, a circular-knitted fabric was prepared from the resulting unstretched yarn of high density polyethylene conjugate fiber, and it was then degummed, subjected to dry heat setting, and dyed by the aforementioned methods. Here, the acidic dye described in the above paragraph M was used for dyeing.
Table 3 shows evaluation results on fiber characteristics of the resulting high density polyethylene conjugate fiber and characteristics of the circular-knitted fabric of the high density polyethylene conjugate fiber. Although the resulting high density polyethylene conjugate fiber had good lightweight property, the acidic dye failed to serve sufficiently in dyeing the ethylene-vinyl acetate copolymer, resulting in very poor color developing property. Furthermore, the coefficient of variation CV of the dispersion diameter of the island domains was so large that deep, vivid color developing property could not be obtained.
Comparative Example 6
Except for using polypropylene (PP) (Novatec FY6, manufactured by Japan Polypropylene Corporation, melting point 170° C.) as sea component and performing both kneading and spinning at a temperature of 190° C., the same procedure as in Comparative example 5 was carried out to produce polypropylene conjugate fiber and a circular-knitted fabric specimen, followed by degumming, dry heat setting, and dyeing.
Table 3 shows evaluation results on fiber characteristics of the resulting polypropylene conjugate fiber and characteristics of the circular-knitted fabric of the polypropylene conjugate fiber. Although the resulting polypropylene conjugate fiber had good lightweight property, the acidic dye failed to serve sufficiently in dyeing the ethylene-vinyl acetate copolymer as in Comparative example 5, resulting in very poor color developing property. Furthermore, the coefficient of variation CV of the dispersion diameter of the island domains was so large that deep, vivid color developing property could not be obtained.
Example 17
Using a twin screw extruder, 80 wt % quantity of polymethylpentene (PMP) (DX820, manufactured by Mitsui Chemicals, Inc., melting point 232° C., MFR 180 g/10 min) used as sea component, 15 wt % of polylactic acid (PLA) (melting point 168° C., weight average molecular weight 145,000) used as island component, and 5 wt % of aminomodified styrene-ethylene-butylene-styrene copolymer (SEBS) (Dynalon 8630P, manufactured by JSR Corporation) used as compatibilizer were kneaded at a kneading temperature of 260° C. The strand discharged from the twin screw extruder was cooled in water and then cut by a pelletizer at intervals of about 5 mm to provide pellets. Here, the melt viscosity ratio between the sea component and the island component was 1.7. The pellets obtained were vacuum-dried at 95° C. for 12 hours and supplied to an extruder type melt spinning machine in which they were melted and discharged through a spinning nozzle (discharge hole size 0.3 mm, discharge hole length 0.6 mm, number of holes 36, round holes) at a spinning temperature 260° C. to provide spun threads. These spun threads were cooled in a cooling air flow with an air temperature of 20° C. and flow speed of 25 m/min, collected while supplying oil from an oil feeder, taken up by a first godet roller rotating at 1,000 m/min, wound up by a winder via a second godet roller rotating at the same speed as the first godet roller to provide an unstretched yarn of 180 dtex-36f. The unstretched yarn obtained was stretched under the conditions of a first hot roller temperature of 90° C., second hot roller temperature of 130° C., and draw ratio of 1.8 to provide a stretched yarn of 100 dtex-36f. The resulting stretched yarn of polymethylpentene conjugate fiber was circular-knitted by a circular knitting machine. A wound-up hank of the stretched yarn and the circular-knitted fabric obtained were separately immersed in chloroform at room temperature for 24 hours, and subsequently taken out of the chloroform, rinsed, and dried to provide porous polymethylpentene fiber.
Table 4 shows evaluation results on the fiber characteristics of the resulting porous polymethylpentene fiber. The porous fiber had a high strength, elongation percentage, and initial tensile resistance and showed good mechanical characteristics. FIG. 1 shows a SEM photograph of a fiber cross section of the porous polymethylpentene fiber. The coefficient of variation CV of the pore diameter was 33%, indicating a high pore size uniformity. Here, the average pore diameter was 0.89 μm and the porosity was 16%. The porous fiber had a specific gravity of 0.73 and accordingly had good lightweight property. In addition, the specific gravity increase rate was 1.3% and collapse of the pores was not caused by twisting, proving a very high hollow retention property.
Examples 18 to 20
Except for changing the weight ratio among the sea component, island component, and compatibilizer, kneading, spinning, and stretching were carried out in the same way as in Example 17, followed by dissolving out the island component to provide porous polymethylpentene fiber.
Table 4 shows evaluation results on the fiber characteristics of the resulting porous polymethylpentene fiber. At all weight ratios for conjugate fiber production, the coefficient of variation CV of the pore diameter was 50% or less, proving high pore size uniformity. As the porosity increases, the specific gravity of the porous fiber decreases, enhancing the lightweight property. In Examples 18 and 19, the specimens had good lightweight property though slightly inferior in mechanical characteristics due to a higher porosity compared to Example 17. In Example 20, the porosity was 8% to ensure acceptable level of lightweight property, though slightly inferior compared to Example 1, and good mechanical characteristics were obtained. In any of Examples 18 to 20, the specific gravity increase rate was less than 10%, ensuring good hollow retention property.
Example 21
Except for using 80 wt % of polymethylpentene (PMP) (RT-18, manufactured by Mitsui Chemicals, Inc., melting point 232° C., MFR 26 g/10 min) as sea component and 20 wt % of polylactic acid (PLA) (melting point 168° C., weight average molecular weight 145,000) as island component, kneading, spinning, and stretching were carried out in the same way as in Example 17, followed by dissolving out the island component to provide porous polymethylpentene fiber.
Table 4 shows evaluation results on the fiber characteristics of the resulting porous polymethylpentene fiber. The coefficient of variation CV of the pore diameter was 34%, proving high pore size uniformity and satisfactory level of lightweight property and hollow retention property.
Example 22
The sea component of polymethylpentene (PMP) (DX820, manufactured by Mitsui Chemicals, Inc., melting point 232° C., MFR 180 g/10 min) and the island component of polylactic acid (PLA) (melting point 168° C., weight average molecular weight 145,000) were vacuum-dried at 95° C. for 12 hours, and then 80 wt % of the sea component and 20 wt % of the island component were supplied to a pressure melter type conjugate spinning machine, in which they were melted separately and discharged at a spinning temperature of 260° C. through a spinning nozzle designed for sea-island conjugate fiber production (discharge hole size 0.3 mm, discharge hole length 0.6 mm, number of holes 36, number of island domains 32, round holes) to provide spun threads. Subsequently, spinning and stretched were carried out in the same way as in Example 17, followed by dissolving out the island component to provide porous polymethylpentene fiber.
Table 4 shows evaluation results on the fiber characteristics of the resulting porous polymethylpentene fiber. The dispersion diameter of the island domains was regulated by the sea-island conjugate spinning and accordingly, the coefficient of variation CV of the pore diameter after dissolving out the island component was a good 17%. Furthermore, the specific gravity increase rate after twisting was 8.1% which suggested blocking of part of pores, but the specimen had satisfactory level of hollow retention property.
Examples 23 to 32
The island component was changed from polylactic acid to other thermoplastic resins as shown in Table 5. The thermoplastic resins used were polyethylene terephthalate (PET) (T701T, manufactured by Toray Industries, Inc., melting point 257° C.) in Example 23, copolymerized PET (PET copolymerized with 8 mol % of 5-sodium sulfoisophthalic acid, melting point 240° C.) in Example 24, nylon 6 (N6) (Amilan CM1017, manufactured by Toray Industries, Inc., melting point 225° C.) in Example 25, polymethyl methacrylate (PMMA) (Acrypet VH000, manufactured by Mitsubishi Rayon Co., Ltd., melting point 140° C.) in Example 26, cellulose acetate propionate (CAP) (CAP-482-20, manufactured by Eastman Chemical Company, melting point 195° C.) in Example 27, cellulose diacetate (CDA) (Acety, manufactured by Daicel, containing 22% diethyl phthalate, melting point 160° C.) in Example 28, hydroxypropyl methyl cellulose (HPMC) (Metolose 65SH, manufactured by Shin-Etsu Chemical Co., Ltd.) in Example 29, polyvinyl alcohol (PVA) (JMR-20H, manufactured by Japan VAM & Poval Co., Ltd., melting point 180° C.) in Example 30, polyethylene oxide (PEO) (Alkox E-30, manufactured by Meisei Chemical Works, Ltd., melting point 65° C.) in Example 31, and polystyrene (PS) (Toyostyrol H-45, manufactured by Toyo Styrene Co., Ltd., melting point 230° C.) in Example 32. For polymethylpentene, RT18 manufactured by Mitsui Chemicals, Inc., was used in Examples 23 to 26 and DX820 manufactured by Mitsui Chemicals, Inc., was used in Examples 27 to 32. The spinning temperature was 290° C. in Examples 23, 260° C. in Examples 24 to 26 and 32, and 240° C. in Examples 27 to 31. In regard to other conditions, kneading, spinning, and stretching were carried out in the same way as in Example 21, followed by preparing a circular-knitted specimen using a circular knitting machine. The dissolving-out of the island component was carried out by immersion in 20 wt % sodium hydroxide aqueous solution at 98° C. for 6 hours in Example 23, in 3 wt % sodium hydroxide aqueous solution at 80° C. for 6 hours in Example 24, in 50 wt % aqueous formic acid solution at room temperature for 24 hours in Example 25, in acetone at room temperature for 24 hours in Examples 26 to 28, in water at room temperature for 24 hours in Examples 29 to 31, and in trichloroethylene at room temperature for 24 hours in Example 32, and then the stretched yarn and circular-knitted specimen were taken out of the solvent, rinsed, and dried to provide porous polymethylpentene fiber.
Table 5 shows evaluation results on the fiber characteristics of the resulting porous polymethylpentene fibers. Regardless of the type of thermoplastic resin used, the resulting porous fiber had a high strength, elongation percentage, and initial tensile resistance and showed good mechanical characteristics. Also regardless of the type of thermoplastic resin used, the thermoplastic resin was found to be dissolved out completely by the immersion in a solvent. Furthermore, although the average diameter of the pores and the coefficient of variation CV of the pore diameter changed with the combination of a sea component and an island component, acceptable levels of lightweight property and hollow retention property were obtained regardless of the thermoplastic resin used.
Examples 33 to 40
Porous polymethylpentene fiber was prepared under different conditions for dissolving out of the island component: the stretched yarn and circular-knitted specimen prepared in Example 21 were used in Examples 33 and 34 and the stretched yarn and circular-knitted specimen prepared in Examples 23 to 28 were used in Examples 35 to 40, respectively. The conditions for dissolving out the island component were as follows: immersion in chloroform at room temperature for 15 hours in Example 33, in chloroform at room temperature for 6 hours in Example 34, in 20 wt % aqueous sodium hydroxide solution at 98° C. for 1 hour in Example 35, in 3 wt % aqueous sodium hydroxide solution at 80° C. for 30 minutes in Example 36, in 50 wt % aqueous formic acid solution at room temperature for 6 hours in Example 37, and in acetone at room temperature for 15 hours in Examples 38 to 40, followed by taking the stretched yarn and circular-knitted specimen out of the solvent, rinsing, and drying. Subsequently, they were degummed, subjected to dry heat setting, and dyed by the aforementioned methods.
Table 6 shows evaluation results on the fiber characteristics of the resulting porous polymethylpentene fiber. In any Example, the dissolving-out time for the island component was shortened so that part of the thermoplastic resin of the island component would remain in the porous polymethylpentene fiber. Comparison among Examples 21, 33, and 34 showed that the content of the remaining thermoplastic resin tended to decrease with an increasing dissolving-out time for the island component. In any of Examples 33 to 40, furthermore, acceptable levels of mechanical characteristics, lightweight property, and hollow retention property were obtained. Furthermore, good color developing property was achieved by dyeing the thermoplastic resin in the porous fiber, and the porous polymethylpentene fiber had a satisfactory level of color developing property.
Comparative Example 7
Except that the polymethylpentene adopted in Example 17 was used alone, spinning and stretching were carried out in the same way as in Example 17 to provide a stretched yarn of polymethylpentene fiber.
Table 7 shows evaluation results on the fiber characteristics of the resulting stretched yarn of polymethylpentene fiber. Though its specific gravity was 0.83, which is smaller as compared with other synthetic fibers, it still exceeds 0.80, suggesting that good lightweight property was not achieved. Since the fiber was solid and had no pores, twisting and untwisting performed as in Example 17 did not cause a change in its specific gravity.
Comparative Example 8
The unstretched yarns obtained in Comparative example 7 was heat-treated at 150° C. and then stretched in the same way as in Example 17 to provide a stretched yarn of polymethylpentene fiber containing pores. These pores resulted from boundary separation between crystalline parts and amorphous parts in the fiber that was caused by stretching.
Table 7 shows evaluation results on the fiber characteristics of the resulting stretched yarn of hollow polymethylpentene fiber. The existence of pores resulting from boundary separation between crystalline parts and amorphous parts that was caused by stretching led to a specific gravity of 0.78, which indicates good lightweight property. On the other hand, the coefficient of variation CV of the diameter of the pores resulting from boundary separation was 80%, which indicates a large variation in pore diameter. Furthermore, because of the large variation of pore diameter, twisting caused collapse of pores and the specific gravity increase rate was a large 12.1%, resulting in inferior hollow retention property. Thus, in the case where pores were formed as a result of boundary separation between crystalline parts and amorphous parts caused by stretching, the variation of pore diameter was large and accordingly, the pore resistance to external force was not at a satisfactory level although it was possible to make the yarn lighter.
Comparative Example 9
Except that the polymethylpentene adopted in Example 17 was used alone and that a hollow type spinning nozzle (discharge hole size 0.3 mm, discharge hole length 0.6 mm, number of holes 36) was used to produce hollow fiber containing one continuous hollow at the center, spinning and stretching were carried out in the same way as in Example 17 to provide a stretched hollow yarn of polymethylpentene fiber in which the hollow accounted for 20%. Here, since the hollow fiber yarn produced in Comparative example 7 had only one hollow, it was not what can be called porous fiber and was essentially different from the one according to the present invention and it was not compatible with the concepts of the coefficient of variation CV of the pore diameter in the fiber cross section and the average diameter of the pores. For reference, 100 of these single yarns were observed to determine their hollow diameters and the coefficient of variation CV of their hollow diameters and the average diameter of the hollows were calculated. The coefficient of variation CV calculated in Comparative example 7 serves as a measure to represent the uniformity in hollow size among the single yarns and it is presented here as reference date.
Table 7 shows evaluation results on the fiber characteristics of the resulting stretched yarn of hollow polymethylpentene fiber. Because hollows existed at the center of each fiber yarn with a volume occupancy of 20%, the specific gravity was 0.66, showing good lightweight property. In addition, since the hollow diameter was regulated by the hollow type spinning nozzle, the coefficient of variation CV of the hollow diameter was 15%, showing high hollow diameter uniformity among the single yarns. When twisted, however, almost all hollows collapsed with a specific gravity increase rate of as high as 19.0%, showing inferior hollow resistance. Thus, the hollow fiber yarns were low in resistance to external force although they had good lightweight property and hollow diameter uniformity among single yarns.
Comparative Example 10
The unstretched yarns obtained in Comparative example 9 was heat-treated at 150° C. and then stretched in the same way as in Example 17 to provide a stretched yarn of polymethylpentene fiber containing pores in addition to a hollow. These pores resulted from boundary separation between crystalline parts and amorphous parts in the fiber that was caused by stretching. In Comparative example 10, the fiber cross section contained both voids originating from the hollow and pores caused by stretching. In Comparative example 10, the diameter of the hollow was excluded and the coefficient of variation CV of the pore diameter and the average diameter of pores were calculated from the diameters of the pores resulting from stretching. Note that the average diameter of the hollows in 100 single yarns was 5.8 μm.
Table 7 shows evaluation results on the fiber characteristics of the resulting stretched yarn of hollow polymethylpentene fiber. Since there were pores resulting from boundary separation between crystalline parts and amorphous parts caused by stretch in addition to the hollows with a volume occupancy of 20% existing at the center of each fiber yarn, the specific gravity was 0.60, showing good lightweight property. On the other hand, the coefficient of variation CV of the diameter of the pores resulting from boundary separation was 65%, which indicates a large variation in pore diameter. When twisted, furthermore, almost all hollows collapse and in addition, the pores resulting from stretching, which had a large pore diameter variation, also collapsed, leading to a specific gravity increase rate of a high 24.7%, which showed inferior hollow resistance. Thus, when voids originating from the hollows coexisted with pores caused by stretching, not only the hollows collapsed but the pores resulting from stretching also collapsed due to a large pore diameter variation, leading to unsatisfactory level of pore resistance to external force, although lightweight property was imparted.
Comparative Examples 11 and 12
In a nitrogen atmosphere, the unstretched yarns prepared in Comparative examples 5 and 6 were heat-treated under constant length conditions at 115° C. for 24 hours and then stretched by a first hot roller and a second hot roller, both controlled at 25° C., at a draw ratio of 1.8. Furthermore, they were stretched 3.4 times in a 2 m long heating cylinder heated at 115° C. and then subjected to relaxing heat setting to an 80% length in a 2 m long heating cylinder heated at 115° C. to provide stretched yarns of pore-containing high density polyethylene conjugate fiber or polypropylene conjugate fiber. These pores resulted from boundary separation between the high density polyethylene or polypropylene and the ethylene-vinyl acetate copolymer in the conjugate fiber that was caused by stretching.
Table 7 shows evaluation results on the fiber characteristics of the resulting stretched yarns of high density polyethylene conjugate fiber or polypropylene conjugate fiber. Because of the existence of pores resulting from boundary separation caused by stretching, the yarns had a very low specific gravity and very good lightweight property. However, the coefficient of variation CV of the diameter of the pores resulting from boundary separation was large, which indicates a large variation in pore diameter. Accordingly, twisting caused collapse of almost all pores, leading to a large specific gravity increase rate and very poor hollow resistance.
TABLE 1
Example
Example
Example
Example
Example
Example
Example
Example
1
2
3
4
5
6
7
8
sea-island
sea component (a)
PMP
PMP
PMP
PMP
PMP
PMP
PMP
PMP
conjugate
island component (b)
PLA
PLA
PLA
PLA
PLA
PLA
PLA
PLA
production
sea/island/compatibilizer [weight
80/20/0
80/20/0
50/50/0
70/30/0
90/10/0
80/20/0
80/20/0
76.2/19.0/4.8
conditions
ratio]
sea-island melt viscosity ratio
1.7
1.1
1.7
1.7
1.7
1.7
1.7
1.7
(ηb/ηa)
sea-island structure formation
alloy type
alloy type
alloy type
alloy type
alloy type
sea-island
sea-island
alloy type
method
fiber fiber
fineness [dtex]
100
100
100
100
100
100
100
100
characteristics
strength [cN/dtex]
2.2
3.0
0.9
1.7
2.5
2.7
2.4
2.6
of polymethyl-
elongation percentage [%]
25
18
30
27
20
23
26
27
pentene
initial tensile resistance [cN/dtex]
29
40
22
24
25
24
25
26
conjugate
average fiber diameter [μm]
19.6
19.8
18.4
19.2
20.2
19.7
19.9
19.6
fiber
dispersion diameter of island
0.89
0.45
1.72
1.36
0.37
2.65
1.33
0.33
component [μm]
coefficient of variation CV of
31
27
43
37
25
8
12
19
dispersion diameter of island
component [%]
specific gravity
0.92
0.92
1.05
0.96
0.87
0.92
0.92
0.92
L* value
32
27
27
30
42
45
37
24
fabric
lightweight property
⊚
⊚
◯
⊚
⊚
⊚
⊚
⊚
characteristics
color developing property
⊚
⊚
⊚
⊚
◯
◯
⊚
⊚
of polymethyl-
washing fastness
⊚
⊚
◯
⊚
⊚
⊚
⊚
⊚
pentene
rubbing fastness
⊚
⊚
◯
⊚
⊚
⊚
⊚
⊚
conjugate
light fastness
⊚
⊚
◯
⊚
⊚
⊚
⊚
⊚
fiber
PMP: polymethylpentene
PLA: polylactic acid
TABLE 2
Example
Example
Example
Example
Example
Example
Example
Example
9
10
11
12
13
14
15
16
sea-island
sea component (a)
PMP
PMP
PMP
PMP
PMP
PMP
PMP
PMP
conjugate
island component (b)
PET
PPT
N6
N66
PMMA
MPP
CAP
CDA
production
Sea/island/compatibilizer [weight
80/20/0
80/20/0
80/20/0
80/20/0
80/20/0
80/20/0
80/20/0
80/20/0
conditions
ratio]
sea-island melt viscosity ratio
2.2
3.7
1.8
0.4
2.5
1.1
1.2
2.4
(ηb/ηa)
sea-island structure formed method
alloy type
alloy type
alloy type
alloy type
alloy type
alloy type
alloy type
alloy type
fiber
fineness [dtex]
100
100
100
100
100
100
100
100
characteristics
strength [cN/dtex]
3.2
2.1
3.0
3.1
2.9
1.9
1.6
1.8
of polymethyl-
elongation percentage [%]
21
30
28
26
25
35
21
24
pentene
initial tensile resistance [cN/dtex]
43
26
18
27
26
33
23
26
conjugate
average fiber diameter [μm]
19.4
19.5
20.0
19.9
19.8
20.5
19.8
19.4
fiber
dispersion diameter of island
1.40
1.85
1.17
0.98
1.67
0.19
0.51
1.52
component [μm]
coefficient of variation CV of
34
45
29
31
39
21
23
36
dispersion diameter of island
component [%]
specific gravity
0.94
0.93
0.89
0.89
0.90
0.85
0.92
0.93
L* value
45
47
43
39
43
23
25
41
fabric
lightweight property
⊚
⊚
⊚
⊚
⊚
⊚
⊚
⊚
characteristics
color developing property
◯
◯
◯
⊚
◯
⊚
⊚
◯
of polymethyl-
washing fastness
⊚
⊚
⊚
⊚
⊚
⊚
⊚
⊚
pentene
rubbing fastness
⊚
⊚
⊚
⊚
⊚
⊚
⊚
⊚
conjugate
light fastness
⊚
⊚
◯
◯
⊚
⊚
⊚
⊚
fiber
PMP: polymethylpentene
PET: polyethylene terephthalate
PPT: polypropylene terephthalate
N6: nylon 6
N66: nylon 66
PMMA: polymethyl-methacrylate
MPP: maleic anhydride modified polypropylene
CAP: cellulose acetate propionate
CDA: cellulose diacetate
TABLE 3
Comparative
Comparative
Comparative
Comparative
Comparative
Comparative
example 1
example 2
example 3
example 4
example 5
example 6
sea-island
sea component (a)
PMP
PMP
PMP
PMP
HDPE
PP
conjugate
island component (b)
—
PLA
PLA
PLA
EVA
EVA
production
sea/island/compatibilizer [weight
—
80/20/0
50/50/0
20/80/0
80/20/0
80/20/0
conditions
ratio]
sea-island melt viscosity ratio
—
1.7
1.7
1.7
2.8
2.3
(ηb/ηa)
sea-island structure formed method
monocomponent
core-sheath
core-sheath
core-sheath
alloy type
alloy type
fiber
fineness [dtex]
100
100
100
100
100
100
characteristics
strength [cN/dtex]
2.5
2.3
1.5
2.4
0.5
0.7
of polymethyl-
elongation percentage [%]
25
25
28
34
597
554
pentene
initial tensile resistance [cN/dtex]
32
35
26
30
13
15
conjugate
average fiber diameter [μm]
20.6
19.7
18.3
17.5
19.3
19.6
fiber
dispersion diameter of island
—
7.51
11.9
15.0
1.67
1.49
component [μm]
coefficient of variation CV of
—
10
13
17
42
35
dispersion diameter of island
component [%]
specific gravity
0.83
0.92
1.05
1.18
0.98
0.95
L* value
65
57
53
51
63
61
fabric
lightweight property
⊚
⊚
◯
Δ
⊚
⊚
characteristics
color developing property
X
Δ
Δ
Δ
X
X
of polymethyl-
washing fastness
⊚
⊚
◯
Δ
Δ
Δ
pentene
rubbing fastness
⊚
⊚
◯
Δ
Δ
Δ
conjugate
light fastness
⊚
⊚
◯
Δ
Δ
Δ
fiber
PMP: polymethylpentene
PLA: polylactic acid
HDPE: high density polyethylene
EVA: ethylene-vinyl acetate copolymer
PP: polypropylene
TABLE 4
Example
Example
Example
Example
Example
Example
17
18
19
20
21
22
sea-island
sea component (a)
PMP
PMP
PMP
PMP
PMP
PMP
conjugate
island component (b)
PLA
PLA
PLA
PLA
PLA
PLA
production
sea-island/compatibilizer [weight
80/15/5
50/45/5
70/25/5
90/8/2
80/20/0
80/20/0
conditions
ratio]
melt viscosity ratio (ηb/ηa)
1.7
1.7
1.7
1.7
1.1
1.7
sea-island structure formation
alloy type
alloy type
alloy type
alloy type
alloy type
sea-island
method
fiber
fineness [dtex] (before dissolving
100
100
100
100
100
100
characteristics
out the island component)
of polymethyl-
fineness [dtex] (after dissolving
79
45
66
88
72
72
pentene
out the island component)
porous fiber
strength [cN/dtex]
2.0
1.5
1.9
3.2
1.8
2.2
elongation percentage [%]
50
42
49
62
20
82
initial tensile resistance [cN/dtex]
23
15
22
25
40
11
content of remaining thermoplastic
0
0
0
0
0
0
resin [%]
average fiber diameter [μm]
31.2
29.7
30.8
32.1
30.9
30.6
average pore diameter [μm]
0.89
1.72
1.36
0.37
0.91
1.50
coefficient of variation CV of pore
33
48
39
25
34
17
diameter [%]
porosity [%]
16
45
24
8
19
20
specific gravity
0.73
0.48
0.64
0.77
0.68
0.68
specific gravity increase rate [%]
1.3
7.9
2.3
0.2
3.4
8.1
lightweight property
◯
⊚
⊚
◯
⊚
⊚
hollow resistance
⊚
◯
⊚
⊚
⊚
◯
PMP: polymethylpentene
PLA: polylactic acid
TABLE 5
Example
Example
Example
Example
Example
23
24
25
26
27
sea-island
sea component (a)
PMP
PMP
PMP
PMP
PMP
conjugate
island component (b)
PET
copolymerized
N6
PMMA
CAP
production
PET
conditions
sea-island/compatibilizer [weight
80/20/0
80/20/0
80/20/0
80/20/0
80/20/0
ratio]
melt viscosity ratio (ηb/ηa)
1.5
1.3
1.8
2.5
1.2
sea-island structure formation
alloy type
alloy type
alloy type
alloy type
alloy type
method
fiber
fineness [dtex] (before dissolving
100
100
100
100
100
characteristics
out the island component)
of polymethyl-
fineness [dtex] (after dissolving
71
71
74
74
72
pentene
out the island component)
porous fiber
strength [cN/dtex]
1.6
1.7
1.7
1.3
1.5
elongation percentage [%]
25
23
22
19
24
initial tensile resistance [cN/dtex]
35
39
43
30
27
content of remaining thermoplastic
0
0
0
0
0
resin [%]
average fiber diameter [μm]
30.6
30.8
31.2
30.5
31.0
average pore diameter [μm]
1.35
1.29
1.22
1.65
0.49
coefficient of variation CV of pore
36
32
34
45
28
diameter [%]
porosity [%]
19
20
20
21
19
specific gravity
0.66
0.67
0.65
0.68
0.64
specific gravity increase rate [%]
2.6
1.9
2.1
6.9
1.1
lightweight property
⊚
⊚
⊚
⊚
⊚
hollow resistance
⊚
⊚
⊚
◯
⊚
Example
Example
Example
Example
Example
28
29
30
31
32
sea-island
sea component (a)
PMP
PMP
PMP
PMP
PMP
conjugate
island component (b)
CDA
HPMC
PVA
PEO
PS
production
sea-island/compatibilizer [weight
80/20/0
80/20/0
80/20/0
80/20/0
80/20/0
conditions
ratio]
melt viscosity ratio (ηb/ηa)
2.4
1.5
1.3
1.1
1.9
sea-island structure formation
alloy type
alloy type
alloy type
alloy type
alloy type
method
fiber
fineness [dtex] (before dissolving
100
100
100
100
100
characteristics
out the island component)
of polymethyl-
fineness [dtex] (after dissolving
72
70
73
73
76
pentene
out the island component)
porous fiber
strength [cN/dtex]
1.4
1.4
1.4
1.3
1.8
elongation percentage [%]
23
22
20
18
26
initial tensile resistance [cN/dtex]
25
22
23
25
40
content of remaining thermoplastic
0
0
0
0
0
resin [%]
average fiber diameter [μm]
31.5
30.7
31.4
31.9
32.7
average pore diameter [μm]
1.55
1.63
1.75
1.80
0.25
coefficient of variation CV of pore
39
49
41
53
19
diameter [%]
porosity [%]
20
19
20
21
19
specific gravity
0.65
0.64
0.66
0.64
0.65
specific gravity increase rate [%]
7.3
7.2
7.5
8.9
0.4
lightweight property
⊚
⊚
⊚
⊚
⊚
hollow resistance
◯
◯
◯
◯
⊚
PMP: polymethylpentene
PET: polyethylene terephthalate
N6: nylon 6
PMMA: polymethyl-methacrylate
CAP: cellulose acetate propionate
CDA: cellulose diacetate
HPMC: hydroxypropyl methyl cellulose
PVA: polyvinyl alcohol
PEO: polyethylene oxide
PS: polystyrene
TABLE 6
Example
Example
Example
Example
Example
Example
Example
Example
33
34
35
36
37
38
39
40
sea-island
sea component (a)
PMP
PMP
PMP
PMP
PMP
PMP
PMP
PMP
conjugate
island component (b)
PLA
PLA
PET
copoly-
N6
PMMA
CAP
CDA
production
merized
conditions
PET
sea-island/compatibilizer [weight
80/20/0
80/20/0
80/20/0
80/20/0
80/20/0
80/20/0
80/20/0
80/20/0
ratio]
melt viscosity ratio (ηb/ηa)
1.1
1.1
1.5
1.3
1.8
2.5
1.2
2.4
sea-island structure formation
alloy type
alloy type
alloy type
alloy type
alloy type
alloy type
alloy type
alloy type
method
fiber
fineness [dtex] (before dissolving
100
100
100
100
100
100
100
100
characteristics
out the island component)
of polymethyl-
fineness [dtex] (after dissolving
79
86
85
81
88
84
78
80
pentene
out the island component)
porous fiber
strength [cN/dtex]
2.0
2.1
2.1
2.0
2.1
1.5
1.7
1.6
elongation percentage [%]
26
26
32
28
30
23
28
26
initial tensile resistance [cN/dtex]
44
46
43
45
50
35
30
29
content of remaining thermoplastic
5
10
10
7
11
8
4
6
resin [%]
average fiber diameter [μm]
31.3
30.7
30.8
30.5
31.5
30.1
31.4
30.3
average pore diameter [μm]
0.81
0.72
1.10
1.12
0.97
1.35
0.45
1.40
coefficient of variation CV of pore
29
27
33
29
25
37
26
36
diameter [%]
porosity [%]
14
10
11
13
10
11
15
15
specific gravity
0.73
0.79
0.79
0.76
0.79
0.76
0.72
0.74
specific gravity increase rate [%]
3.2
2.7
3.8
4.1
3.5
2.6
0.9
4.7
L* value
42
37
49
51
48
49
38
54
lightweight property
◯
◯
◯
◯
◯
◯
◯
◯
hollow resistance
⊚
⊚
⊚
⊚
⊚
⊚
⊚
⊚
color developing property
◯
⊚
◯
◯
◯
◯
⊚
◯
levelness of dyeing
⊚
⊚
◯
⊚
⊚
◯
⊚
◯
dyeing specks
◯
⊚
⊚
⊚
⊚
◯
◯
◯
PMP: polymethylpentene
PLA: polylactic acid
PET: polyethylene terephthalate
N6: nylon 6
PMMA: polymethyl-methacrylate
CAP: cellulose acetate propionate
CDA: cellulose diacetate
TABLE 7
Comparative
Comparative
Comparative
Comparative
Comparative
Comparative
example 7
example 8
example 9
example 10
example 11
example 12
sea-island
sea component (a)
PMP
PMP
PMP
PMP
HDPE
PP
conjugate
island component (b)
—
—
—
—
EVA
EVA
production
sea-island/compatibilizer [weight
100/0/0
100/0/0
100/0/0
100/0/0
80/20/0
80/20/0
conditions
ratio]
melt viscosity ratio (ηb/ηa)
—
—
—
—
2.8
2.3
sea-island structure formation
monocomponent
monocomponent
hollow type
hollow type
alloy type
alloy type
method
fiber
fineness [dtex]
100
94
63
57
26
24
characteristics
strength [cN/dtex]
2.7
2.9
2.1
0.8
3.7
4.5
of polymethyl-
elongation percentage [%]
46
40
25
11
48
45
pentene
initial tensile resistance [cN/dtex]
24
27
22
52
27
31
porous fiber
average fiber diameter [μm]
22.5
21.8
25.4
23.9
8.6
8.8
average pore diameter [μm]
—
0.50
(8.7)
0.42
0.95
0.91
coefficient of variation CV of pore
—
80
(15)
65
76
73
diameter [%]
porosity [%]
—
5
20
28
61
57
specific gravity
0.83
0.78
0.66
0.60
0.38
0.41
specific gravity increase rate [%]
0.0
12.1
19.0
24.7
82.1
79.6
lightweight property
X
◯
⊚
⊚
⊚
⊚
hollow resistance
—
X
X
X
X
X
PMP: polymethylpentene
HDPE: high density polyethylene
EVA: ethylene-vinyl acetate copolymer
PP: polypropylene
INDUSTRIAL APPLICABILITY
The polymethylpentene conjugate fiber according to the present invention includes lightweight polymethylpentene fiber having deep, vivid color developing property. Furthermore, the porous polymethylpentene fiber according to the present invention is very light in weight, highly uniform in pore diameter, and high in pore resistance to external force. Accordingly, the polymethylpentene conjugate fiber and porous polymethylpentene fiber that can be obtained according to the present invention can be adopted favorably as fiber structures such as woven and knitted fabrics, nonwoven fabrics, spun yarns, and wadding.
EXPLANATION OF NUMERALS
1 : porous fiber
2 : pores | Provided are a polymethylpentene conjugate fiber, which is capable of imparting to a lightweight polymethylpentene fiber an ability to develop a vivid and deep color, and a porous polymethylpentene fiber, which has a lightweight, a high pore diameter uniformity and a high porosity retention ratio against an external force, said polymethylpentene conjugate fiber and said porous polymethylpentene fiber being appropriately usable as a fiber structure for woven knitted goods, non-woven fabrics, yarns, cotton waddings, etc. The polymethylpentene conjugate fiber is characterized by having an island-in-sea structure wherein the sea component comprises a polymethylpentene-based resin and the island component comprises a thermoplastic resin. The porous polymethylpentene fiber, which comprises a polymethylpentene-based resin, is characterized in that the coefficient of variation (CV) of pore diameter at the fiber cross section is 1-50%. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 90,313 filed Nov. 1, 1979, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to certain 2,4-diaminoquinazolines. Particularly, the invention relates to certain 7-alkoxy-2,4-diaminoquinazolines which are further substituted by a 6-chloro group and/or an 8-alkoxy group, their use as antihypertensive agents, pharmaceutical compositions thereof and intermediates for their production.
2. Description of the Prior Art
U.S. Pat. Nos. 3,511,836; 3,635,979 and 3,663,706 disclose 6,7-dimethoxy-2,4-diaminoquinazolines of the formula ##STR2## where Z is a nitrogen-containing heterocyclic group. One of these compounds, 2-[4-(2-furoyl)piperazin-1-yl]-4-amino-6,7-dimethoxyquinazoline, is a clinically useful antihypertensive agent and is marketed under the generic name "prazosin," the pharmacology of which is discussed in Constantine et al., "Hypertension: Mechanisms and Management," edited by Onesti, Kin and Moyer, Grune and Stratton, 1973, pp. 429-444.
U.S. Pat. Nos. 3,669,968 and 3,769,286 disclose 6,7,8-trialkoxy-2,4-diaminoquinazolines in which the 2-amino group is substituted by certain alkyl and hydroxy substituted alkyl groups or is a heterocyclic group such as piperidino or 4-substituted piperazino. One of these compounds is known by the generic name "trimazosin" and has the formula ##STR3## Trimazosin is also an active antihypertensive agent, see e.g., Vlachikis et al., Current Therapeutic Research, 17, 564 (1975). However, it is less potent than prazosin. Althuis et al., J. Med. Chem., 20, 146 (1977) have shown the 6-0-demethyl derivative is a major metabolite of prazosin of considerably lower blood pressure lowering activity. The 7-0-demethyl derivative is a less prevalent metabolite.
U.S. Pat. Nos. 3,920,636 and 4,044,135 disclose homopiperazinoquinazoline compounds as antihypertensive agents.
Several patents have issued which disclose antihypertensive compounds of the general formula ##STR4## U.S. Pat. No. 4,001,237 claims compounds wherein R a is an oxazole, isoxazole, thiazole or isothiazole radical.
In U.S. Pat. No. 4,001,238, such compounds are disclosed wherein R a is of the formula ##STR5##
U.S. Pat. No. 3,780,040 discloses 3,4-dihydroquinazoline analogs of the above formula wherein R a is 2-thienyl.
In U.S. Pat. No. 4,026,894 and U.S. Pat. No. 4,112,097, R a is a 2-tetrahydrofuryl or 2-tetrahydropyranyl moiety. U.S. Pat. No. 4,060,615 claims compounds in which R a is cycloalkyl having 3 to 8 carbon atoms and cycloalkenyl having 4 to 8 carbon atoms. U.S. Pat. No. 4,101,548 is concerned with 1,2,3-thiadiazole amides of the above formula wherein R a is ##STR6## and R b is hydrogen, lower alkyl, NH 2 or NHCO 2 R c L in which R c is lower alkyl.
6,7-Dimethoxy-2-(4-thiomorpholin-1-yl) 4-aminoquinazolines and derivatives in which the 2-substituent is ##STR7## are disclosed as antihypertensive agents in U.S. Pat. No. 4,115,565.
British Pat. No. 1,530,768 discloses prazosin analogs in which the 2-amino group is of the formula ##STR8## where R e is phenyl, substituted phenyl, furyl, thienyl or 5-alkylthio-1,3,4-oxadiazol-2-yl.
French Pat. No. 2,321,890 discloses analogs of prazosin in which the 2-amino substituent is a piperidino or piperazino group substituted in the 3 or 4 position.
The compounds of the invention are highly potent antihypertensive agents having improved duration of action since they are not susceptible to metabolic demethylation at the 6-position with resultant loss of activity as is the case with prazosin. In addition, the invention compounds have improved water solubility when compared to prazosin. They can therefore be administered intraveneously, particularly for emergency purposes and are uniformly absorbed by all patients.
SUMMARY OF THE INVENTION
The present invention discloses new 2,4-diaminoquinazoline compounds and processes for their production. The new 2,4-diaminoquinazolines possess valuable pharmacological properties and other aspects of the invention relate to pharmaceutical compositions for oral or parenteral administration to a mammal comprising one or more of said new compounds and a pharmaceutically acceptable carrier, as well as a method for treating hypertension which comprises orally or parenterally administering to mammals in need of such treatment an antihypertensive effective amount of a compound of the invention.
The compounds of the invention are also useful for their vasodilation properties, as antiglaucoma agents and in the treatment of congestive heart failure.
The novel compounds disclosed are of the formula ##STR9## wherein Y 1 is hydrogen or chloro, Y 2 is OR and Y 3 is hydrogen or OR such that when Y 1 is hydrogen, Y 3 is OR and when Y 1 is chloro, Y 3 is hydrogen or OR, and the pharmaceutically acceptable acid addition salts thereof;
R is alkyl having from one to three carbon atoms;
R 1 and R 2 are the same or different and when taken separately are each a member selected from the group consisting of hydrogen, alkyl having from 1 to 5 carbon atoms, cycloalkyl having from 3 to 8 carbon atoms; alkenyl having from 3 to 5 carbon atoms, alkynyl having from 3 to 5 carbon atoms, hydroxy substituted alkyl having from 2 to 5 carbon atoms and when taken together with the nitrogen atom to which they are attached R 1 and R 2 form ##STR10## where X 1 is a member selected from the group consisting of S(O) t , CHOR 6 , --(CH 2 ) p -- and CHR 7 , and X 2 is a member selected from the group consisting of X 1 , O, NR 3 , NCOR 4 and NCOOR 5 , where
m is 2 or 3,
n is 2 or 3,
p is 1 to 3,
t is 0, 1 or 2;
R 3 is a member selected from the group consisting of hydrogen, alkyl having from 1 to 6 carbon atoms, alkenyl from 3 to 5 carbon atoms, alkynyl having from 3 to 5 carbon atoms, hydroxy substituted alkyl having from 2 to 5 carbon atoms, cycloalkyl having from 3 to 8 carbon atoms, --(CH 2 ) q C 6 H 4 R 8 and --(CH 2 ) q C 10 H 6 R 8 where q is 0 or 1;
R 4 is a member selected from the group consisting of hydrogen, alkyl having from 1 to 6 carbon atoms, alkenyl having from 3 to 5 carbon atoms, cycloalkyl and cycloalkylmethyl wherein said cycloalkyl has from 3 to 8 carbon atoms, ##STR11## R 10 , CH 2 R 10 and (CH 2 ) q C 6 H 4 R 8 where A is S or O, q as defined above and R 10 is a member selected from the group consisting of ##STR12## where r is 1 or 2; R 5 is a member selected from the group consisting of alkyl having from 1 to 7 carbon atoms, alkenyl having 3 to 5 carbon atoms, cycloalkyl having from 3 to 8 carbon atoms, hydroxy substituted alkyl having from 2 to 5 carbon atoms, CH 2 C 6 H 4 R 8 , CH 2 C 10 H 6 R 8 , CH 2 R 10 and CH 2 O-pyridyl;
R 6 is a member selected from the group consisting of hydrogen, C 6 H 4 R 8 , --(CH 2 ) p ZR 15 , alkyl having from 1 to 6 carbon atoms, and said alkyl substituted by a member selected from the group consisting of Cl, F, Br, OH, CH 3 O, SO 2 CH 3 and NHSO 2 CH 3 , where p and A are as previously defined and Z is a member selected from the group consisting of O, S, SO, SO 2 , NH and NR 16 ;
R 7 is a member selected from the group consisting of alkyl having from one to six carbon atoms, hydroxyalkyl having from one to five carbon atoms, --(CH 2 ) q C 6 H 4 R 8 and COC 6 H 4 R 8 ;
R 8 is a member selected from the group consisting of H, Cl, Br, F, CH 3 , CH 3 O, CF 3 , OH, SO 2 CH 3 and NHSO 2 CH 3 ;
R 9 is a member selected from the group consisting of H, Cl, CH 3 , C 2 H 5 and phenyl;
R 11 is hydrogen or methylthio and
R 12 is a member selected from the group consisting of H, NH 2 alkyl having from one to four carbon atoms and NHCO 2 R 14 ;
R 14 is alkyl having from one to four carbon atoms;
R 15 is a member selected from the group consisting of alkyl having from one to four carbon atoms, C 6 H 4 R 8 and C 10 H 6 R 8 ; and R 16 is hydrogen or alkyl having from one to four carbon atoms.
Preferred compounds of the invention include the compounds of formula (I) wherein Y 1 , Y 2 and Y 3 are as defined above and NR 1 R 2 is ##STR13## where R 4 is a member selected from the group consisting of ##STR14## and cycloalkyl having from 3 to 8 carbon atoms and A, r and R 11 are as previously defined. Also preferred are the compounds of formula (I) wherein Y 1 , Y 2 and Y 3 are as defined above and NR 1 R 2 is ##STR15## where R 5 is hydroxy substituted alkyl having from 2 to 5 carbon atoms.
Particularly preferred compounds of the invention are:
2-[4-(2-furoyl)piperazin-1-yl]-4-amino-7,8-dimethoxyquinazoline,
2-[4-(2-furoyl)piperazin-1-yl]-4-amino-6-chloro-7-methoxyquinazoline,
2-[4-(2-furoyl)piperazin-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinazoline,
2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]-4-amino-7,8-dimethoxyquinazoline,
2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]-4-amino-6-chloro-7-methoxyquinazoline and
2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinazoline, and their hydrochloride salts.
The invention further provides certain intermediates useful in the preparation of the compounds of formula (I). These intermediates are of the formula ##STR16## where Y 1 , Y 2 and Y 3 are as defined above.
The term "pharmaceutically acceptable" used herein to describe an acid addition salt of a compound of formula (I) refers to those salts having anionic species of a variety of relatively non-toxic inorganic or organic acids. The anion does not contribute appreciably to the toxicity of the salt or to its pharmacological activity. Illustrative of such salts are those formed with acetic, lactic, succinic, maleic, tartaric, citric, gluconic, ascorbic, benzoic, cinnamic, fumaric, sulfuric, phosphoric, hydrochloric, hydrobromic, hydroiodic, sulfamic, sulfonic acids such as methanesulfonic, benzenesulfonic, p-toluenesulfonic, and related acids. Preparation of the mono-acid addition salts may be carried out in conventional manner by treating a solution or suspension of the free base in a reaction inert organic solvent with one chemical equivalent of the acid or if the di-acid addition salt is desired, at least two chemical equivalents of the acid. Conventional concentration or crystallization techniques are employed in isolating the salts.
The compounds of formula (I) are especially useful as antihypertensive agents having significant advantages over the prior art. The Y 1 substituent, at the 6-position of the invention compounds, is either hydrogen or chloro, groups which are not prone to metabolic attack. Consequently, the invention compounds are not subject to facile metabolic demethylation with resultant loss of activity, as has been shown for prazosin. Accordingly, the compounds of formula (I) have greater duration of action than prazosin and other 6,7-dimethoxy- and 6,7,8-trimethoxyquinazoline antihypertensive agents known in the art.
The invention compounds also have significantly greater water solubility than prazosin and as a result of their improved solubility, are uniformly absorbed by all patients. Furthermore, they can be administered in time release form, as well as parenterally, including intraveneously.
DETAILED DESCRIPTION OF THE INVENTION
The antihypertensive compounds of the invention are represented by either of the formulae ##STR17## wherein Y 1 , Y 2 , Y 3 , R, R 1 and R 2 are as previously defined. They are prepared by synthetic methods described below.
Scheme I, below, outlines a preferred reaction sequence. In the first step a 4-alkoxyanthranilic acid of formula (IX) containing the desired substituents Y 1 and Y 3 as defined above is cyclized to the corresponding 2,4-dioxoquinazoline of formula (X). The cyclization is brought about by reacting the compound (IX) with sodium or potassium cyanate or urea according to the procedure of Curd et al., Jour. Chem. Soc., 777 (1947) for the corresponding 6,7-dimethoxyquinazolinediones. Of course, as will be apparent to one skilled in the art, the anthranilic acids of formula (IX) may be replaced in this reaction by the corresponding compounds in which the carboxylic acid moiety is replaced by a CONH 2 , CN, or carboxylic ester group with satisfactory results. The cyclized compounds of formula (X) are novel compounds, of value as intermediates for preparing the antihypertensive compounds of the invention. As will be recognized by one skilled in the art, they may also be represented as the corresponding tautomeric 2,4-dihydroxyquinazolines. ##STR18##
In preparing the intermediates of formula (X), the starting material (IX) is suspended in a polar solvent in the presence of acid, preferably water-acetic acid, and a 2-4 molar excess of the cyanate salt, e.g., potassium cyanate or urea added. The resulting mixture is then heated at a temperature of from about room temperature up to the reflux temperature of the solvent until reaction is substantially complete. Typical reaction times are from about 1 to 24 hours. The mixture is then cooled, made alkaline with sodium hydroxide or potassium hydroxide and the alkaline mixture heated again at a temperature of from about 70° to 100° C. for 1 to 5 hours. The resulting sodium salt of the product (X) is then acidified and isolated by standard methods known in the art.
The intermediate of formula (X) is then reacted with a mixture of phosphorous pentachloride and phosphorous oxychloride or the corresponding phosphorous bromides to prepare the corresponding 2,4-dihaloquinazolines. The preferred embodiment, in which the above phosphorous chlorides are employed, is depicted in Scheme I to provide the intermediates of formula (XI) in which R, Y 1 and Y 3 are as defined above. Typically the dione (X) and a 2 to 4 molar excess each of phosphorous pentachloride and phosphorous oxychloride are heated at reflux for 2 to 6 hours, the residual phosphorous oxychloride evaporated and the residue slurried in a reaction inert organic solvent, for example, chloroform or dichloromethane, and poured into ice-water. Insoluble material is removed and the product isolated from the organic layer by evaporation or precipitation by addition of a non-solvent, for example, hexane, to precipitate the dichloro compound of formula (XI).
The key 2-chloro-4-aminoquinazoline intermediates of formula (XII) are provided by reacting equimolar amounts of ammonia and 2,4-dichloroquinazoline (XI) in the presence of a reaction inert organic solvent. Examples of suitable reaction inert solvents are ethyl ether, tetrahydrofuran, chloroform and benzene. A preferred solvent is tetrahydrofuran. In ordinary practice a preferred excess of ammonia of from one to ten moles would be used in order to shift the reaction toward completion. The temperature at which this reaction can be carried out is from about 25° to 200° C. for a period of from one to 48 hours. A preferred reaction temperature and time for this reaction would be about 25° to 60° C. for about five hours. Upon completion of the reaction the product is recovered by conventional means. For instance, the solvent can be evaporated and the crude solid can be triturated with water or precipitated from dilute aqueous acid in crystalline form and subsequently recrystallized from any number of organic solvents such as methanol, dimethylformamide or their mixtures with water.
Conversion of the 2-chloroquinazoline intermediate of formula (XII) to the desired compound of formula (III) is accomplished by contacting the intermediate (XII) with an equimolar amount of an amine of the formula R 1 R 2 NH in the presence of an aqueous or an organic solvent. A small molar excess of amine is generally employed. Preferred organic solvents for this reaction include polar solvents like tetrahydrofuran, dioxane, dimethylacetamide, dimethylformamide; alcohols such as methanol, ethanol and isoamyl alcohol and ketones such as methylethylketone and methylisobutylketone. Particularly preferred solvents are isoamyl alcohol and methylisobutylketone. The reaction mixture is heated preferably at a temperature of from about 60° to 160° C. for from one to 65 hours. Particularly preferred reaction temperatures are from about 100° to 140° C. and temperatures in this range are conveniently obtained by maintaining the reaction mixture at the reflux temperature of the particularly preferred solvents. At such temperature the reaction is ordinarily complete in from about two hours to two days.
Alternate procedures for preparing the compounds of the invention may also be used with satisfactory results. For example, the alternate methods disclosed in U.S. Pat. No. 3,511,836 for preparation of prazosin and its analogs can also be used with the appropriate starting materials to provide the invention compounds of formula (I). These methods are enumerated and discussed briefly below.
1. 2-Amino-4-chloroquinazolines (XXIX) prepared by methods analogous to those described in U.S. Pat. No. 3,511,836 for the corresponding 6,7-dialkoxy-compounds may be reacted with ammonia under conditions described above for the conversion of compounds (XI) to (XII) with resultant formation of the desired product of formula (I) where Y 1 , Y 2 Y 3 , R 1 and R 2 are as defined above. ##STR19##
2. The quinazolinedione of formula (X) can be reacted with a reagent such as phosphorous pentasulfide or the like to form the corresponding 2,4-quinazolinedithione which are in turn reacted with an alkyl or benzyl halide to form the corresponding 2,4-dithioalkylquinazoline or 2,4-dithiobenzylquinazoline. This is then reacted with ammonia by the procedure previously described for the reaction of the 2,4-dichloroquinazolines (XI) to provide the corresponding 4-amino-2-thioalkyl (or thiobenzyl) quinazoline (XX). The latter compound is then converted to the desired compound (I) by employing conditions previously described for the formation of compound (I) from 2-chloro compounds of formula (XII). ##STR20## where Y 1 , Y 2 , Y 3 , R 1 and R 2 are as previously defined.
3. Compounds of formula (I) wherein NR 1 R 2 forms a heterocyclic moiety of the formula ##STR21## where X 2 is NR 3 , NCOR 4 or NCOOR 5 and m, n, R 3 , R 4 and R 5 are as previously defined, but R 3 is other than hydrogen, can also be prepared from the compound wherein X 2 is NH, for example NR 1 R 2 is piperazino, by acylation, alkylation or carbonyloxylation. ##STR22## The compound (XXI) is reacted with a compound of formula R 3 --X 3 , R 4 COX 3 or X 3 COOR 5 , where R 3 , R 4 and R 5 are as defined above and X 3 is a leaving group, preferably the halides, Cl or Br. When the preferred halides are employed it is advantageous to use at least a slight molar excess to ensure complete reaction. The intermediate (XXI) and reagnet of formula R 3 X 3 , R 4 COX 3 or X 3 COOR 5 are contacted in the presence of a reaction inert organic solvent, for example, benzene, tetrahydrofuran, acetone methylethyl ketone, methylisobutyl ketone, 1,2-dimethoxyethane or diethyleneglycol dimethylether. A preferred such solvent is methylisobutyl ketone. The reaction may be carried out successfully over a wide range of temperatures. However, a temperature in the range of about 0° C. up to the reflux temperature of the solvent is preferred for reasons of efficiency and convenience. At such a preferred temperature the reaction is ordinarily complete in from about 30 minutes to six hours. The resulting solid product is then isolated as either the hydrohalide or the free base by conventional methods and purified, if desired, by crystallization, column chromatography or the like.
4. In this method the 2-aminobenzonitrile intermediate of formula (XIV) is reacted with a guanidine of the formula ##STR23## where R 1 and R 2 are as defined above. The benzonitrile (XIV) and an equivalent amount, but preferably a molar excess, of the guanidine are contacted in the presence of a reaction inert organic solvent, for example, ethylene glycol, diethyleneglycol, dimethylformamide, dimethylsulfoxide or diethyleneglycol dimethylether, at a temperature of from about 120°-180° C. for from about four to 15 hours. The desired product of formula (I) is then isolated by well known methods, for example, the solvent is evaporated, the residue contacted with water and the precipitated product is filtered, recrystallized and dried. The reaction is illustrated as follows: ##STR24##
The guanidine starting materials are prepared by methods well known in the art. For example, the amine of formula R 1 R 2 NH is reacted with cyanogen bromide to form the corresponding N-cyano-compound which, in turn, is reacted with hydroxylamine, followed by catalytic hydrogenation using the methods and conditions of Carrington, Jour. Chem. Soc., London, 2527 (1955) for the conversion of anthranilonitrile into 2-aminobenzamidine.
Variations of the above method can also be carried out employing either of the following starting materials in place of the 2-aminobenzonitrile (XIV). ##STR25## The 2-chlorobenzonitriles are obtained, for example, by diazotization of (XIV) in the presence of cuprous chloride. The 2-aminobenzamidines are obtained, for example, by the method of Carrington, above.
5. Chloro-4-alkoxy-7,8-disubstituted quinazolines, which are prepared by methods described by Curd et al., Jour. Chem. Soc., 775 (1974) for the isomeric 2-chloro-4-alkoxy-6,7-disubstituted quinazolines, can be reacted with an amine, R 1 R 2 NH, to obtain the corresponding 2-aminoquinazolines. The 4-alkoxy substituent is then replaced by NH 2 by reaction with ammonia as described above for the 4-chloro compounds of formula (XXIX). This reaction sequence is exemplified below for a 2-chloro-4-ethoxyquinazoline starting material. ##STR26## Y 1 , Y 2 , Y 3 , R 1 and R 2 are as previously defined. The 4-thioalkylquinazolines corresponding to the above 4-alkoxy compounds can also be employed as starting materials in this sequence.
6. The compounds of the invention are also provided by methods disclosed in U.S. Pat. No. 3,935,213 for prazosin, trimazosin and analogs thereof as set forth below where Y 1 , Y 2 , Y 3 , R 1 and R 2 are as previously defined; ##STR27## A 1 is selected from the group consisting of CN and C(═NH)XR 3 wherein X is O or S and R 3 is alkyl having from one to six carbon atoms; and Q is CN or --C(═NH)NH 2 . Preferably the reaction is carried out in the presence of from about 0.5 to 5 molar equivalents of a basic catalyst, e.g., sodium hydride, potassium ethoxide or triethylamine, and at a temperature in the range of from about 50° to 180° C. The products of formula (I) are isolated by well known methods, for example, those described in U.S. Pat. No. 3,935,213.
7. Compounds of formula (I) are also obtained by employing the appropriate starting material of formula (XIV) in the process described in Belgian Pat. No. 861,821 and 861,822 for synthesis of prazosin. The method is outlined in Scheme II. The o-aminobenzonitrile (XIV) wherein Y 1 , Y 2 and Y 3 are as defined above is reacted with at least an equimolar amount of thiophosgene in a reaction inert organic solvent, e.g., 1,2-dichloroethane. To the mixture is added a base, e.g. calcium carbonate, water and the mixture stirred typically at about 0°-5° C., then warmed to about room temperature until reaction is substantially complete. ##STR28## The o-isothiocyanatobenzonitrile (XV) produced is isolated in crude form for use in the next step. The intermediate (XV), dissolved in a reaction inert organic solvent, typically ethyl acetate, is contacted with the amine of formula R 1 R 2 NH, where R 1 and R 2 are as defined above, at a temperature below 0° C., preferably at about -30° to -5° C. to obtain the o-thioureidobenzonitrile (XVI). This is then contacted with a methylating agent, for example methyl iodide or methyl bromide, and the resulting S-methyl hydrohalide salt treated with a mild base to obtain the S-methylthioformamidate of formula (XVII) which is cyclized by reaction with anhydrous ammonia in the presence of a polar solvent and an alkali metal amide to provide the desired compounds of formula (I). Preferred polar solvents for the cyclization are formamide or N,N-dimethylformamide. Also preferred for the final step are use of from 1 to 3 equivalents of alkali metal amide, especially sodium amide and a temperature of from about 100° to 150° C.
8. In U.S. Pat. No. 4,138,561 a novel process for preparing prazosin and trimazosin is disclosed. This method is also suitable for preparation of the compounds of the present invention as shown below. ##STR29##
The starting materials of formula (XXXIII) wherein Y 1 , Y 2 and Y 3 are as previously defined are known compounds [see, for example, Gibson et al., J. Chem. Soc., 111, 79 (1917); Munavalli et al., Bull. Soc. Chim., France, 3311 (1966); Chem. Abstr., 66, 46303s (1967); and German Offenlegungsschrift No. 1,959,577; Chem. Abstr., 75, 63397d (1971)]. The starting material (XXXIII) is converted to the isothiocyanate (XXXIV) as described above for intermediate (XV) and this is reacted with an amine R 1 R 2 NH wherein R 1 and R 2 are as defined above to provide the subsituted thiourea (XXXV) by the method described above for intermediate (XVI). The intermediate (XXXV), in turn, is reached with an alkylating agent, Y 4 X 4 to obtain an intermediate of formula (XXXVI) in which Y 4 is alkyl having from one to four carbon atoms or an aryl derivative containing electron withdrawing groups, for example, 2,4-dinitrophenyl, and X 4 is a member selected from the group Cl, Br, I, alkyl-SO 4 having from one to four carbon atoms, C 6 H 5 SO 2 , F 3 CSO 2 and FSO 3 . An especially preferred alkylating agent, Y 4 X 4 , is methyl iodide. Alternatively, as disclosed in U.S. 4,138,561, phosgene may be used in the first step in the above reaction sequence of Scheme III, wherein each of the intermediates (XXXIV) to (XXXVI) is the corresponding compound in which an atom of oxygen replaces the sulfur atom shown therein. The intermediate of formula (XXXVI) is then reacted with cyanamide to provide the corresponding carboxamidine intermediate of formula (XXXVII).
Alkylation of thiourea derivatives (XXXV) and subsequent reaction with cyanamide is normally carried out in a reaction inert organic solvent. Suitable solvents include dioxane, tetrahydrofuran, dimethyl sulfoxide, and the alkanols having from one to five carbon atoms. These reactions are preferably carried out at a temperature of from about 25° to 100° C. for a period of about 0.5 to 24 hours. The intermediate of formula (XXXVII) may also be obtained by alternate procedures described in U.S. Pat. No. 4,138,561.
The conversion of carboxamidine intermediates (XXXVII) to the desired quinazolines of formula (I) is carried out by reaction with cyclizing reagents such as phosphorus trichloride or phosphorus pentachloride in a solvent amount of phosphorus oxychloride. Other phosphorus halides and phosphorus oxyhalides such as phosphorus tribromide and phosphorus pentabromide in a solvent amount of phosphorus oxybromide may be employed. The ring closure may also be carried out by reacting the intermediate (XXXVII) with acidic reagents such as aqueous hydrogen chloride, hydrogen chloride in phosphorus oxychloride, trichloroacetic acid or Lewis acid catalysts such as ZnCl 2 , FeCl 3 , AlCl 3 , AlBr 3 , and the like.
With respect to carrying out the reaction with phosphorus halides, approximately equimolar amounts of the carboxamidine (XXXVII) and phosphorus halides are employed with convenient amount of phosphorus oxyhalide relative to the amount of starting material (XXXVII). The term "solvent amount" as used herein refers to a quantity of phosphorus oxychloride or phosphorus oxybromide sufficient to provide good mixing and handling characteristics with respect to the reaction mixtures. For this purpose a ratio of from about 2 to 15 ml. of the phosphorus oxyhalide for each gram of carboxamidine reactant of formula (XXXVII) is generally preferred.
Commonly used temperatures for carrying out the cyclization reaction range from about 25° to 125° C. with a preferred temperature of from about 70° to 100° C. As will be appreciated by those skilled in the art, reaction times and conditions required for cyclization of intermediates (XXXVII) to form the desired products of formula (I) vary according to several factors such as temperature and reaction time. For example, at lower temperatures, longer reaction periods are needed, while at higher temperatures, the cyclization reaction is completed in a shorter time. Reaction periods of from about 0.5 to 24 hours can be used, however a period of from about 1 to 3 hours is preferred at the above mentioned preferred reaction temperatures.
The required starting materials of formula (IX) for the procedure of Scheme I, above are obtained by the reaction sequences illustrated in Schemes IV, V and VI below, for the case where R is CH 3 . ##STR30##
In the reaction schemes above and below, for the sake of convenience, the lower case letters a, b and c are used after the Roman numerals for the compounds shown to denote the following:
a. Y 1 =H, Y 2 =Y 3 =OR where R is alkyl having from one to three carbon atoms.
b. Y 1 =Cl, Y 2 =Y 3 =OR, R is as defined above.
c. Y 1 =Cl, Y 2 =OR as defined above, Y 3 =H. ##STR31##
In the reaction sequence of Scheme IV vanillin is acetylated with, for example acetic anhydride or acetyl chloride by well known methods and the acetylated intermediate nitrated to obtain 4-acetoxy-3-methoxy-2-nitrobenzaldehyde (V). The acetyl group is removed by hydrolysis, for example by treatment with an aqueous strong base such as sodium hydroxide, followed by acidification to provide the 4-hydroxy-3-methoxy-2-nitrobenzaldehyde intermediate of formula (VI). This intermediate is then alkylated with one of the well known alkylating agents commonly employed for the conversion of phenolic groups to the corresponding alkyl ethers. Examples of such alkylating agents are dimethylsulfate, diethyl sulfate, methylbromide, n-propyl iodide and ethyl iodide. In the case illustrated in Scheme IV a methylating agent is employed to provide 3,4-dimethoxy-2-nitrobenzaldehyde, (VII). Compounds in which the two ether groups are different are obtained by use of, for example, diethyl sulfate or n-propyl iodide as the alkylating agent. When ethyl vanillin or n-propyl vanillin are employed in place of vanillin as starting material in this reaction sequence the corresponding compounds are likewise obtained wherein the corresponding alkoxy groups are 4,5-diethoxy, 4,5-dipropoxy, 4-ethoxy-5-methoxy, 4-ethoxy-5-n-propoxy, 4-n-proproxy-5-methoxy and 4-n-propoxy-5-ethoxy.
The dialkoxy intermediate of formula VII, e.g., is then oxidized to the corresponding carboxylic acid. While a wide variety of oxidizing agents and conditions are known in the art to bring about oxidation of aromatic aldehydes to the corresponding carboxylic acids, preferred oxidizing conditions are those employing potassium permanganate in aqueous acetone at the reflux temperature of the mixture. The 2-nitro-4,5-dialkoxy-benzoic acid intermediate, e.g. the compound of formula (VIII) is isolated by known means and reduced to the corresponding 2-amino acid, for example, the compound of formula (IXa, R=CH 3 ), by well known means, e.g. by catalytic hydrogenation employing a noble metal hydrogenation catalyst. A preferred catalyst is palladium.
The intermediate of formula (IXa) is useful as a starting material in the reaction sequence shown in Scheme I, above, to provide the corresponding invention compounds of formula (Ia) or (IIIa). Alternatively, as shown in Scheme IV, the intermediates (IXa) serve as a starting material for the corresponding 5-chloro intermediates of formula (IXb). The carboxylic acid is first esterified to form an alkyl ester, e.g. the methyl or ethyl ester, by well known means. The ester is then chlorinated employing, for example chlorine or sulfuryl chloride and the latter reagent is preferred for reasons of efficiency and ease of handling. Typically a slight molar excess, e.g. a 20% molar excess, of sulfuryl chloride is added to a cooled solution of the intermediate carboxylate ester of the acid (IXa) in a chlorinated hydrocarbon solvent, e.g. chloroform, methylene chloride or 1,2-dichloroethane, the resulting mixture is allowed to warm to room temperature, then heated at reflux until reaction is substantially complete, e.g. from one hour to 24 hours. The crude 5-chloro ester is then hydrolyzed, e.g. by means of sodium hydroxide as described above to provide the corresponding 5-chloro acid of formula (IXb).
The starting 5-chloro-5-alkoxyanthranilic acids of formula (IXc) are obtained as shown in Scheme V. 4-Methoxy-2-nitroaniline (XVIII) is treated with sodium nitrite in concentrated hydrochloric acid under conditions well known to those skilled in the art, to form an intermediate diazonium salt to which is then added an aqueous solution containing an equimolar amount of cuprous cyanide and a molar excess, typically a 50% excess, of potassium cyanide while warming the reaction mixture on a steam bath. The product 4-cyano-3-nitroanisole (XIX) is then isolated and then hydrolyzed, e.g. in the presence of aqueous sulfuric or hydrochloric acid to obtain the carboxylic acid of formula (XXI). This, in turn, is hydrogenated as described above for the conversion of compound (VIII) to (IXa) to provide 4-methoxy anthranilic acid (XXII) and the latter chlorinated to provide the desired compound (IXc, R=CH 3 ) employing the conditions described above for the conversion of compounds of formula (IXa) to 5-chloro compounds (IXb).
As shown in Scheme V, other synthetic routes may be employed to provide the desired starting material of formula (IXc). In one such alternate method the 4-cyano-3-nitroanisole (XIX) is hydrogenated as previously defined for conversion of compound (VIII) to compound (IXa) to provide the aminonitrile of formula (XX). This is chlorinated as described above for the conversion of compounds (IXa) to (IXb) and the resulting 5-chloro nitrile (XIVc, R=CH 3 ) is hydrolyzed as described for the preparation of compound (XXI) from nitrile (XIX), to provide the desired compound (IXc, R=CH 3 ).
Another route shown in Scheme V involves oxidation of the starting material 4-methyl-3-nitroanisole with potassium permanganate to provide the intermediate (XXI) which is converted to compound (IXc) as previously described.
As will be obvious to those skilled in the art when the methoxy group present in the starting materials of formula (XVIII) and (XXIII) employed in Scheme V is replaced by an ethoxy or n-propoxy group, the corresponding compounds of formula (IXc) are obtained wherein R is C 2 H 5 or n-C 3 H 7 , respectively.
Similarly, replacement of either one or both of the methoxy groups present in the starting material of formula (XXV) employed in Scheme VI by ethoxy or n-propoxy provides the corresponding compounds of formula (IXa) or (IXb).
The starting materials of formula (XIV) employed in the reaction sequence illustrated in Scheme II for the preparation of the compounds of the invention, are prepared as shown in Scheme V for compounds (XIVc) and in Scheme VI for compounds (XIVa) and (XIVb), and as described above.
Many of the requisite amines of formula R 1 R 2 NH wherein R 1 and R 2 are as previously defined are known compounds, see for example, the references mentioned above as prior art. Those that are new are prepared by methods which will be apparent to those skilled in the art. For example, the amines of formula ##STR32## where a is 1, 2, or 3, n is 2, or 3 and R 6 is as defined above are obtained by reacting the appropriate corresponding N-protected amine wherein R 6 is hydrogen with, for example, a compound of the formula (R 6 )'-Hal where (R 6 )' has any of the values assigned above for R 6 except hydrogen and Hal is Cl, Br, I or other known leaving groups such as SO 3 CH 3 . The reaction is typically carried out employing an equimolar amount of a metal hydride, for example sodium hydride and in the presence of a reaction inert organic solvent, e.g. dimethylformamide. The N-protecting group is then removed to provide the desired amine of the above formula. Typically, protecting groups such as acetyl or benzyl are employed. The former being removed by hydrolysis and the latter by catalytic hydrogenation, e.g., employing a palladium catalyst.
Alternatively, the above compounds wherein R 6 contains an ether moiety can be obtained by the reaction sequence below which illustrates the preparation of 4-(ethoxy-n-propoxy)piperidine. ##STR33##
Many of the requisite amines of formula ##STR34## wherein a, n and R 7 are as defined above are known compounds. Those that are not known are prepared by well known methods. For example, the R 7 -substituted piperidines may be obtained by catalytic hydrogenation of the corresponding R 7 -substituted pyridines. The cyclic amines of the above formula wherein R 7 is alkyl having from one to six carbon atoms are provided by reacting the appropriate N-protected aminoketone with an alkyl Grignard reagent, for example, as outlined below. ##STR35## The catalytic hydrogenolysis of the tertiary hydroxy group is often facilitated by prior acetylation.
The desired cyclic amines wherein R 7 is hydroxyalkyl having from two to five carbon atoms are obtained, for example by methods outlined below. ##STR36## The compounds of formula (XXXVIII) wherein R 7 is hydroxymethyl are obtained by e.g. lithium aluminum hydride reduction of the corresponding aldehydes or carboxylic acid esters.
The compounds of formula (XXXVIII) wherein R 7 is R 8 C 6 H 4 (CH 2 ) 8 wherein q is 0 or 1 and R 8 is as previously defined may also be obtained via a Grignard reaction as shown below, for example. ##STR37##
The starting materials of formula (XXXVIII) wherein R 7 is R 8 C 6 H 4 CO may be obtained, for example, by Friedel-Crafts acylation of R 8 C 6 H 5 by an N-protected carboxylic acid halide as illustrated below. ##STR38## The piperidine derivatives of the latter formula are also obtained by employing the corresponding pyridine carboxylic acid halides and compound of formula R 8 C 6 H 5 in the Friedel-Crafts acylation followed by hydrogenation of the pyridine moiety.
The cyclic aminocarboxylic acid precursors of the above N-protected cyclic aminoacid halides are either readily available or may be obtained by the well known Dieckmann reaction followed by hydrolysis and decarboxylation of the resulting alpha-ketoester to provide a cyclic ketone intermediate which can be converted to the desired carboxylic acid by a variety of methods, e.g. ##STR39##
In the above reaction sequence a and n are as defined above and R 13 is a suitable amino protecting group, e.g. benzyl or acetyl. As will be recognized by one skilled in the art, in the above reaction sequence when R 13 is benzyl the ketone reduction step is preferably carried out by a metal hydride, e.g. sodium borohydride or lithium aluminum hydride, and removal of the benzyl group is accomplished by hydrogenolysis.
Use of a longer chain R 13 -protected iminodicarboxylate esters in the above Dieckmann reaction can be employed to provide the corresponding R 13 -protected amino ketones of the formula ##STR40## which upon Wolff-Kishner reduction and deprotection provides starting materials of formula ##STR41## where a, n and p are as defined above.
The antihypertensive activity of the compounds of the invention is shown by their ability to lower the blood pressure of conscious spontaneously hypertensive rats and conscious renally hypertensive dogs, when administered orally at doses of up to 30 mg./kg.
For instance, 2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinazoline, a typical and preferred compound of the invention, has been found to lower blood pressure in renally hypertensive dogs to a statistically significant degree, e.g., when this compound is administered orally at doses as low as 0.2 mg./kg., it effected a decrease of 30 mm. Hg after 4 hours with no significant change in heart rate or other side effect. Similarly, at the same dosage 2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]-4-amino-6-chloro-7-methoxyquinazoline, a particularly preferred compound of the invention, caused a reduction of 40 mm. Hg after one hour which increased only by 20 mm. Hg 6 hours after administration; and another particularly preferred compound: 2-[4-(2-furoyl)-1-piperazinyl]-4-amino-6-chloro-7-methoxyquinazoline effected a reduction in blood pressure of 40 mm. Hg which increased by only 5 mm. Hg six hours after the oral dose (0.2 mg./hg.) had been administered. Again, no significant heart rate change or other unwanted side effect was noted with the latter two compounds.
In addition to their useful antihypertensive activity, the compounds of the invention also demonstrate activity in standard tests designed to show vasodilator activity, antiglaucoma activity and utility in the treatment of congestive heart failure.
The compounds of the invention can be administered alone, but will generally be administered in admixture with a pharamaceutical carrier selected with regard to the intended route of administration and standard pharmaceutical practice. For example, they can be administered orally in the form of tablets containing such excipients as starch or lactose, or in capsules either alone or in admixture with excipients, or in the form of elixirs or suspensions containing flavoring or coloring agents. They can be injected parenterally, for example, intramuscularly, intravenously or subcutaneously. For parenteral administration, they are best used in the form of a sterile aqueous solution which can contain other solutes, for example, enough salt or glucose to make the solution isotonic. For treatment of glaucoma, they can be administered topically as well as by the above mentioned routes of administration. For topical application, a compound of the invention is admixed under sterile conditions with a pharmaceutically-acceptable liquid carrier or solvent such as water, a glycol or mixtures thereof, and toxicity adjustors, preservatives and buffers added as required. The resulting solution or dispersion is then sterilely filtered and used to fill sterile bottles.
The invention also provides a pharmaceutical composition comprising an antihypertensive effective amount of a compound of the formula (I) or pharmaceutically acceptable acid addition salts thereof together with a pharmaceutically acceptable diluent or carrier.
The compounds of the invention can be administered to humans for the treatment of hypertension or congestive heart failure by either the oral or parenteral routes, and may be administered orally at dosage levels approximately within the range 1 to 500 mg./day for an average adult patient (70 kg.), given in a single dose or up to 3 divided doses. Intravenous dosage levels would be expected to be about one-half to one-tenth of the daily oral dose. Thus for an average adult patient, individual oral doses in the tablet or capsule form will be approximately in the range from 0.5 to 250 mg. of the active compound. Variations will necessarily occur depending on the weight and condition of the subject being treated and the particular route of administration chosen as will be known to those skilled in the art.
The invention yet further provides a method of treating an animal, including a human being, having hypertension, which comprises administering to the animal an antihypertensive effective amount of a compound of the formula (I) or pharmaceutically acceptable acid addition salt thereof or pharmaceutical composition as defined above.
The following Examples illustrate the invention.
EXAMPLE 1
7,8-Dimethoxyquinazoline-2,4-dione (Xa)
Acetic acid (177.4 ml., 3.1 moles) was added to a vigorously stirred suspension of 3,4-dimethoxyanthranilic acid (436.5 g., 2.21 moles) in 10 liters of water. Then 2.24 liters of 20% potassium cyanate (5.53 moles) solution was gradually added and the mixture was stirred for one hour at 40° C. After cooling the reaction mixture to 20° C., 3.54 kg. sodium hydroxide pellets were added maintaining the temperature below 40° C. The reaction mixture was heated to 90° C. for 45 minutes and then slowly cooled in an ice bath. The sodium salt of the product was filtered, resuspended in 6 liters of water, acidified with concentrated hydrochloric acid (370 ml.), cooled and filtered to yield 404 grams (82%) of the product. Recrystallization from dimethylformamide gave colorless crystals, M.P. 314°-6° C.
Analysis, Percent Calcd. for C 10 H 10 N 2 O 4 : C, 54.05; H, 4.54; N, 12.61. Found: C, 53.96; H, 4.57; N, 12.63.
EXAMPLE 2
2,4-Dichloro-7,8-dimethoxyquinazoline (XIa)
A mixture of 7,8-dimethoxyquinazoline-2,4-dione (400 g., 1.80 moles), phosphorous pentachloride (750 g., 3.60 moles) and phosphorous oxychloride (4 liters was refluxed under nitrogen for three hours. Phosphorus oxychloride (POCl 3 ) was removed in vacuo and residual POCl 3 was removed as an azeotrope with toluene. The solid residue was slurried in eight liters of dichloromethane and the slurry slowly added to ice-cold H 2 O. The suspension was stirred and unreacted starting material (54.0 g.) was filtered off. The organic layer was separated, dried over sodium sulfate and filtered. The solution was concentrated and then 4 liters of hexane was slowly added. Upon cooling, a pale yellow product (346 g., 80.4%) was collected by filtration and recrystallized from toluene/ether, M.P. 153°-5° C.
Analysis, Percent Calcd. for C 10 H 8 Cl 2 N 2 O 2 : C, 46.35; H, 3.11; N, 10.81. Found: C, 46.14; H, 3.33; N, 10.60.
EXAMPLE 3
2-Chloro-4-amino-7,8-dimethoxyquinazoline (XIIa)
Ammonia was passed into a solution of 2,4-dichloro-7,8-dimethoxyquinazoline (287 g., 1.11 moles) in tetrahydrofuran (6 liters) for five hours at room temperature. After stirring an additional hour the suspension was concentrated in vacuo to 2 liters and filtered. The solid was suspended in 2 liters of water, filtered, washed with water and cold methanol. Recrystallization from dimethylformamide/water yielded 164 g. (62%) of pure product, M.P. 300°. (dec.).
Analysis, Percent Calcd. for C 10 H 10 ClN 3 O 2 : C, 50.11; H, 4.21; N, 17.53. Found: C, 50.07; H, 4.24; N, 17.58.
EXAMPLE 3A
When the appropriate starting material selected from those provided in Preparation I are employed in place of 3,4-dimethoxyanthranilic acid in the procedure of Example 1 and in each case the resulting product carried through the procedures of Examples 2 and 3, the following compounds are provided in a like manner.
______________________________________ ##STR42## Y.sup.2 Y.sup.3______________________________________ C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O CH.sub.3 O C.sub.2 H.sub.5 O n-C.sub.3 H.sub.7 O CH.sub.3 O C.sub.2 H.sub.5 O CH.sub.3 O n-C.sub.3 H.sub.7 O C.sub.2 H.sub.5 O______________________________________
EXAMPLE 4
2-[4-(2-Furoyl)piperazine-1-yl]-4-amino-7,8-dimethoxyquinazoline hydrochloride
A mixture of 2-chloro-4-amino-7,8-dimethoxyquinazoline (3.00 g., 12.5 mmoles) and 1-(2-furoyl)piperazine (2.71 g., 15.0 mmoles) was refluxed in 80 ml. isoamyl alcohol for two hours and then cooled in an ice-bath. The resulting white product was collected by filtration and recrystallized from methanol/ether to yield 4.53 g. (79%) of pure final product, M.P. 251° C. The water solubility was found to be 20 mg./ml.
Analysis, Percent Calcd. for C 19 H 21 N 5 O 4 .HCl: C, 54.34; H, 5.28; N, 16.68. Found: C, 54.14; H, 5.21; N, 16.42.
EXAMPLE 5
A. 6-Chloro-7,8-dimethoxyquinazoline-2,4-dione (Xb)
Acetic acid (10.5 g., 0.175 mole) was added to a vigorously stirred suspension of 5-chloro-3,4-dimethoxyanthranilic acid (28.9 g., 0.125 mole) in 600 ml. water. Then 506 ml. 5% potassium cyanate (0.312 mole) solution was gradually added and stirred 1 hour at 40° C. After cooling the reaction mixture to 20° C., 175 g. (4.37 moles) of sodium hydroxide pellets were added while maintaining the temperature below 40° C. The reaction mixture was heated to 90° C. for 45 minutes. Upon cooling in an ice bath, the sodium salt of the product precipitated, was filtered, resuspended in 125 ml. water, acidified with concentrated hydrochloric acid, cooled and filtered to yield 25.8 g. (80%) of colorless, pure product, M.P. 272°-3° C.
Analysis, Percent Calcd. for C 10 H 9 ClN 2 O 4 : C, 46.79; H, 3.53; N, 10.92. Found: C, 46.87; H, 3.60; N, 10.90.
B. 6-Chloro-7-methoxyquinazoline-2,4-dione (XVIII)
Similarly, 6-chloro-7-methoxyquinazoline-2,4-dione was prepared from 5-chloro-4-methoxyanthranilic acid in 83% yield, M.P. 356°-8° C.
Analysis, Percent Calcd. for C 9 H 7 ClN 2 O 3 : C, 47.70; H, 3.11; N, 12.36. Found: C, 47.72; H, 3.44; N, 12.27.
EXAMPLE 6
A. 2,4,6-Trichloro-7,8-dimethoxyquinazoline (XIb)
A mixture of 6-chloro-7,8-dimethoxyquinazoline-2,4-dione (25.5 g., 0.099 mole), phosphorous pentachloride (41.4 g., 0.199 mole) and 300 ml. phosphorous oxychloride was refluxed under nitrogen for three hours. Phosphorous oxychloride was removed in vacuo and residual POCl 3 was azeotroped with toluene. The reddish-orange solid was dissolved in 200 ml. dichloromethane and the solution was slowly added to ice-cold water. After stirring for 10 minutes the organic layer was separated, washed with water, and dried over sodium sulfate. The filtrate was concentrated and 150 ml. hexane was added slowly to precipitate the product as a pale yellow solid which was recrystallized from toluene/ether to afford 18.0 g. (62% yield), M.P. 154°-5° C.
Analysis, Percent Calcd. for C 10 H 7 Cl 3 N 2 O 2 : C, 40.91; H, 2.40; N, 9.55. Found: C, 41.05; H, 2.48; N, 9.61.
B. 2,4,6-Trichloro-7-methoxyquinazoline (XIX)
Refluxing 6-chloro-7-methoxyquinazoline-2,4-dione with PCl 5 in POCl 3 as described above afforded 2,4,6-trichloro-7-methoxyquinazoline in 74% yield, M.P., 150°-2° C.
Analysis, Percent Cald. for C 9 H 5 Cl 3 N 2 O: C, 41.02; H, 1.91; N, 10.63. Found: C, 40.90; H, 2.01; N, 10.54.
EXAMPLE 7
A. 2,6-Dichloro-4-amino-7,8-dimethoxyquinazoline (XIIb)
Ammonia was passed into a solution of 2,4,6-trichloro-7,8-dimethoxyquinazoline (31.4 g., 0.107 mole) in 650 ml. dry tetrahydrofuran for one hour at room temperature. After stirring for an additional hour, the suspension was concentrated in vacuo and filtered. The solid was resuspended in water, filtered, washed with water and methanol. Recrystallization from dimethylformamide/water yielded 23.7 g. (81%) of the desired product, M.P., 360° C.
Analysis, Percent Calcd. for C 10 H 9 Cl 2 N 3 O 2 : C, 43.82; H, 3.31; N, 15.33. Found: C, 43.95; H, 3.53; N, 15.35.
B. 2,6-Dichloro-4-amino-7-methoxyquinazoline (XX)
Reaction of 2,4,6-trichloro-7-methoxyquinazoline with ammonia as described above afforded 2,6-dichloro-4-amino-7-methoxyquinazoline as a white solid, M.P., 300° C. in 58% yield.
Analysis, Percent Calcd. for C 9 H 7 Cl 2 N 3 O: C, 44.28; H, 2.89; N, 17.22. Found: C, 44.12; H, 3.16; N, 17.19.
EXAMPLE 8
A. 2-[4-(2-Furoyl)piperazine-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinazolinehydrochloride (XIIIb)
A mixture of 2,6-dichloro-4-amino-7,8-dimethoxyquinazoline (1.50 g., 5.47 mmole) and 1-(2-furoyl)piperazine (1.08 g., 5.99 mmole) was refluxed in 40 ml. isoamyl alcohol for 2 hours and then cooled overnight. The resulting solid was filtered and recrystallized from methanol/ether to yield 1.83 g. (74%) of pure final product, M.P., 208°-9° C.
Analysis, Percent Calcd. for C 19 H 20 ClN 5 O 4 .HCl1/2.H 2 O: C, 49.25; H, 4.79; N, 15.17. Found: C, 49.03; H, 4.61; N, 15.35.
Water Solubility: 8 mg./ml.
B. 2-[4-(2-Furoyl)piperazine-1-yl]-4-amino-6-chloro-7-methoxyquinazoline hydrochloride
The title compound was prepared similarly by refluxing 2,6-dichloro-4-amino-7-methoxyquinazoline and 1-(2-furoyl)piperazine in isoamyl alcohol, M.P. 229°-31° C., 79% yield.
Analysis, Percent Calcd. for C 18 H 18 ClN 5 O 3 .HCl.H 2 O: C, 48.88; H, 4.79; N, 15.83. Found: C, 49.47; H, 4.70; N, 15.62.
Water Solubility: 5 mg/ml.
EXAMPLE 9
A. 2-Methyl-2-hydroxypropyl 4-[4-amino-6-chloro-7,8-dimethoxyquinazolin-2-yl]piperazine-1-carboxylate hydrochloride
A mixture of 2,6-dichloro-4-amino-7,8-dimethoxyquinazoline (1.50 g., 5.47 mmole) and 2-methyl-2-hydroxypropyl-4-piperazine-1-carboxylate (1.22 g., 6.03 mmole) was refluxed in 30 ml. methylisobutylketone for two days. The yellowish solid was filtered, resuspended in 40 ml. acetone and stirred for 15 minutes. The filtered solid was decolorized with charcoal and recrystallized twice from ethanol/ether to yield 1.47 g. (57%) of final product, M.P., 211°-3° C.
Analysis Percent Calcd. for C 19 H 26 ClN 5 O 5 .HCl; C, 47.90%; H, 5.50%; N, 14.70%. Found: C, 47.70%; H, 5.74; N, 14.36%.
Water Solubility: 35 mg./ml.
B. 2-ethyl-2-hydroxypropyl 4-[4-amino-6-chloro-7-methoxyquinazolin-2-yl]-piperazine-1-carboxylate hydrochloride [XXI, R 1 +R 2 =--COOCH 2 C(OH) (CH 3 ) 2 ]
The title compound was prepared similarly by refluxing 2,6-dichloro-4-amino-7-methoxy quinazoline and 2-methyl-2-hydroxypropyl-4-piperazine-1-carboxylate in methyl isobutyl ketone for 4 days, M.P. 243°-5° C., 69% yield.
Analysis Percent Calcd. for C 18 H 24 ClN 5 O 4 .HCl.H 2 O C, 46.55%; H, 5.86%; N, 14.08%. Found: C, 46.89%; H, 5.67%; N, 15.22%.
Water Solubility: 6 mg./ml.
C. 2-[4-(1,4-Benzodioxan-2-carbonyl)piperazin-1-yl]-4-amino-6-chloro-7-methoxyquinazoline hydrochloride
The title compound was prepared by the procedure of Part A, above, by refluxing 2,6-dichloro-4-amino-7-methoxyquinazoline and N-(1,4-benzodioxan-2-carbonyl)piperazine in methylisobutylketone, M.P. 194°-196° C.
EXAMPLE 10
When the appropriate N-substituted piperazine is employed in the procedure of Example 4 in place of 1-(2-furoyl)piperazine, the analogous products tabulated below are obtained as the hydrochloride salts except as otherwise noted.
__________________________________________________________________________ ##STR43## Elemental Analysis Solubility Empirical Calcd.: W M.P. °C. mg./ml. Formula Found: % C % H % N__________________________________________________________________________COOR.sup.5 ;COOCH.sub.3 244-5 40 C.sub.16 H.sub.21 N.sub.5 O.sub.4 . 50.56 5.78 18.25 49.69 5.74 18.24COOCH.sub.2 CH.sub.3 238-40 50 C.sub.17 H.sub.23 N.sub.5 O.sub.4 . 50.74 6.13 17.41 . 0.25 H.sub.2 O 50.83 6.03 17.25COO(CH.sub.2).sub.2 CH.sub.3 229-30 140 C.sub.18 H.sub.25 N.sub.5 O.sub.4 . 52.48 6.36 17.00 52.28 6.37 16.82COO(CH.sub.2).sub.3 CH.sub. 3 224-6 90 C.sub.19 H.sub.27 N.sub.5 O.sub.4 . 53.58 6.63 16.44 53.28 6.34 16.22COO(CH.sub.2).sub.4 CH.sub.3 114-6 40 C.sub.20 H.sub.29 N.sub.5 O.sub.4 . 54.60 6.87 15.92 54.73 6.98 15.92COOCH.sub.2 CH(CH.sub.3).sub.2 212-3.5 40 C.sub.19 H.sub.27 N.sub.5 O.sub.4 . 53.58 6.63 16.44 53.82 6.70 15.79COOR.sup.5 :COO(CH.sub.2).sub.2 CH(CH.sub.3).sub.2 192 25 C.sub.20 H.sub.29 N.sub.5 O.sub.4 . 54.60 6.87 15.92 54.99 7.18 15.91COOCH.sub.2 C(CH.sub.3).sub.2 165-70 -- C.sub.19 H.sub.27 N.sub.5 O.sub.4 . 48.66 6.66 14.93OH . 0.5 H.sub.2 O 48.81 6.59 14.83 ##STR44## 237-8 150 C.sub.19 H.sub.25 N.sub.5 O.sub.4 . HCl . 0.5 H.sub.2 O 52.71 53.03 6.29 5.95 16.18 16.16 ##STR45## 237-8.5 11 -- -- -- -- ##STR46## -- -- -- -- -- -- ##STR47## 251-3 -- C.sub.15 H.sub.19 N.sub.5 O.sub.3 . HCl . H.sub.2 48.45 48.30 5.96 5.65 18.83 18.72 ##STR48## 192-201 50 C.sub.21 H.sub.23 N.sub.5 O.sub.3 . HCl . 0.5 H.sub.2 O 57.46 56.99 5.74 5.66 15.96 15.87 ##STR49## -- -- C.sub.19 H.sub.26 N.sub.6 O.sub.3 -- -- -- ##STR50## 150 (dec) 15 C.sub.23 H.sub.25 N.sub.5 O.sub.5 . HCl . H.sub.2 54.59 54.27 5.58 5.39 13.84 13.85 ##STR51## -- -- -- -- -- -- ##STR52## 158-61 -- C.sub.20 H.sub.27 N.sub.5 O.sub.3 (free 62.32 62.10 7.06 7.27 18.17 18.19R.sup.3 : CH.sub.2 CH.sub.2 OH 205-8 95 C.sub.16 H.sub.23 N.sub.5 O.sub.3 . 48.71 6.54 18.94 50.01 6.55 18.85CH.sub.2 C.sub.6 H.sub.5 194-8 100 C.sub.21 H.sub.25 N.sub.5 O.sub.2 . 55.80 6.69 15.49 (dec) . 2 H.sub.2 O 55.38 6.49 15.33C.sub.6 H.sub.5 185-7 25 C.sub.20 H.sub.23 N.sub.5 O.sub.2 . 59.77 6.02 17.43 59.10 6.09 17.233-CF.sub.3 C.sub.6 H.sub.4 218-9 8 C.sub.21 H.sub.22 N.sub.5 O.sub.2 F.sub.3 . 53.67 4.93 14.90 53.97 4.88 15.12CH.sub.2 CHCH.sub.2 195- 6 50 C.sub.17 H.sub.23 N.sub.5 O.sub.2 . 54.46 6.72 18.68 . 0.5 H.sub.2 O 53.73 6.46 18.44__________________________________________________________________________
EXAMPLE 11
2-[4-(2-Furoyl-homopiperazine-1-yl]-4-amino-7,8-dimethoxyquinazoline hydrochloride
A. N-(2-Furoyl)homopiperazine
Homopiperazine (70 g., 0.70 mole) in 160 ml. water was treated with 6 N hydrochloric acid to adjust to pH 5.5 Furoyl chloride (79.5 g., 0.60 mole) and 25% (w/w) aqueous sodium hydroxide solution were added simultaneously to maintain a pH of 4.5-5.5. Then additional sodium hydroxide was added to bring the mixture to pH 9.5. The solution was extracted with chloroform, dried over anhydrous potassium carbonate and distilled to afford 63 g. of product, B.P. 124°-130° C. at 10 mm.
B. 4-Amino-2-dimethoxyquinazoline (1.76 g., 7.3 mole), N-(2-furoyl)homopiperazine (1.50 g., 7.7 mole) and 40 ml. of isoamyl alcohol were combined and the mixture heated at reflux under a nitrogen atmosphere for 1.5 hours. After cooling to room temperature, the mixture was stirred for one hour, filtered and the precipitated product washed with ether and recrystallized from methanol/ether to afford 2.15 g. of the title compound, M.P. 182°-183° C.
Analysis, Percent Calcd. for C 20 H 23 N 5 O 4 .HCl.0.5H 2 O: C, 54.23; H, 5.69; N, 15.81. Found: C, 53.84; H, 5.40; N, 15.49.
The solubility in water was found to be 30 mg./ml.
EXAMPLE 12
2-[4-(2-Tetrahydrofuroyl)homopiperazin-1-yl]-4-amino7,8-dimethoxyquinazoline hydrochloride
A. N-(2-Tetrahydrofuroyl)homopiperazine
N-[2-Furoyl)homopiperazine (33.0 g.) in 200 ml. of ethanol was hydrogenated over 5% rhodium-on-carbon catalyst at three atmospheres pressure. The catalyst was removed by filtration and the product distilled to give the desired product, B.P. 135° at 1 mm.
B. 4-Amino-2-chloro-7,8-dimethoxyquinazoline (2.10 g., 8.75 mmole), N-(2-tetrahydrofuroyl)homopiperazine (1.9 g., 9.58 mmole) and 50 ml. of isoamyl alcohol were mixed and heated at reflux under nitrogen for 2.5 hours. The solvent was removed by evaporation in vacuo, the residue dissolved in water and filtered through a mixture of activated carbon and diatomaceous earth. The filtrate was adjusted to an alkaline pH by addition of sodium bicarbonate solution, extracted four times with 50 ml. portions of ethyl acetate and the extracts dried over sodium sulfate. The solvent was evaporated and the residue chromatographed on 30 g. of silica gel, eluting with chloroform/ethanol. The fractions containing the desired product (free base) were combined and evaporated to afford the free base as a foam, 1.0 g. The free base was dissolved in ether, saturated hydrogen chloride and filtered to obtain the title compound, M.P. 130° (dec.).
Analysis, Percent Calcd. for C 20 H 27 N 5 O 4 .HCl.0.50H 2 O: C, 53.74; H, 6.54; N, 15.67. Found: C, 53.56; H, 6.68; N, 15.44.
Water Solubility: 120 mg./ml.
EXAMPLE 13
A. 2-(4-Benzylpiperidin-1-yl)-4-amino-7,8-dimethoxyquinazoline hydrochloride
4-Amino-2-chloro-7,8-dimethoxyquinazoline (2.40 g., 10 mmole), 4-benzylpiperidine (1.93 g., 11 mmole) and 50 ml. of isoamyl alcohol were heated at reflux under a nitrogen atmosphere for two hours and cooled to room temperature. Diethyl ether (50 ml.) was added and the mixture allowed to stand in the refrigerator for two days. The precipitated solid was collected by filtration and recrystallized from ethanol/diethyl ether to afford 2.50 g. (60%) of the title compound, M.P. 216°-217° C.
Analysis, Percent Calc'd. for C 22 H 26 O 2 N 4 .HCl C, 63.68; H, 6.56; N, 13.50 Found: C, 63.78; H, 6.67; N, 13.89.
Water Solubility: 6 mg./ml.
EXAMPLE 14
Employing the appropriately substituted 2-chloro-(or 2-bromo) 4-amino quinazoline and amine of formula ##STR53## in the procedure of Example 13 the following products are obtained. ##STR54## where a is 1 or m and m and n are 2, or 3.
______________________________________Y.sup.1Y.sup.2 Y.sup.3 a n R.sup.7______________________________________H CH.sub.3 O CH.sub.3 O 1 2 CH.sub.3Cl CH.sub.3 O H 1 2 CH.sub.3 (CH.sub.2).sub.5Cl CH.sub.3 O CH.sub.3 O 1 2 (CH.sub.3).sub.2 CHCH.sub.2H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 1 2 C.sub.6 H.sub.5Cl C.sub.2 H.sub.5 O H 1 2 C.sub.6 H.sub.5 CH.sub.2Cl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 1 2 3-CH.sub.3 C.sub.6 H.sub.4H nC.sub.3 H.sub.7 O CH.sub.3 O 1 3 (CH.sub.3).sub.2 CHCl nC.sub.3 H.sub.7 O H 1 3 CH.sub.3 (CH.sub.2).sub.4Cl nC.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O 1 3 3-FC.sub.6 H.sub.4H CH.sub.3 O H 1 3 4-CH.sub.3 OC.sub.6 H.sub.4 CH.sub.2Cl CH.sub.3 O CH.sub.3 O 2 2 4-HOC.sub.6 H.sub.4Cl CH.sub.3 O CH.sub. 3 O 2 2 3-CH.sub.3 SO.sub.2 C.sub.6 H.sub.4H CH.sub.3 O CH.sub.3 O 2 2 2-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.4 CH.sub.2Cl CH.sub.3 O H 2 3 CH.sub.3 CH.sub.2Cl CH.sub.3 O CH.sub.3 O 2 3 4-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.4H C.sub.2 H.sub.5 O H 2 3 CH.sub.3 (CH.sub.2).sub.3Cl CH.sub.3 O CH.sub.3 O 2 3 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2Cl CH.sub.3 O CH.sub.3 O 2 3 4-FC.sub.6 H.sub.4H CH.sub.3 O n-C.sub.3 H.sub.7 O 3 3 CH.sub.3Cl n-C.sub.3 H.sub.7 O H 3 3 C.sub.6 H.sub.5Cl CH.sub.3 O H 3 3 C.sub.6 H.sub.5 CH.sub.2H CH.sub.3 O CH.sub.3 O 3 3 4-CH.sub.3 C.sub.6 H.sub.4Cl CH.sub.3 O CH.sub.3 O 1 3 2-ClC.sub.6 H.sub.4 COCl CH.sub.3 O H 1 3 C.sub.6 H.sub.5 COH CH.sub.3 O CH.sub.3 O 1 2 4-BrC.sub.6 H.sub.4 COCl CH.sub. 3 O H 1 2 4-HOC.sub.6 H.sub.4 COCl CH.sub.3 O CH.sub.3 O 2 2 4-CF.sub.3 C.sub.6 H.sub.4 COH CH.sub.3 O CH.sub.3 O 2 3 4-FC.sub.6 H.sub.4 COCl CH.sub.3 O H 3 3 3-CH.sub.3 SO.sub.2 C.sub.6 H.sub.4 COCl CH.sub.3 O H 1 3 C.sub.6 H.sub.5 COH CH.sub.3 O CH.sub.3 O 1 2 HOCH.sub.2Cl CH.sub.3 O CH.sub.3 O 1 2 HOCH.sub.2 CH.sub.2Cl CH.sub.3 O H 1 2 (CH.sub.3).sub.2 C(OH)CH.sub.2H CH.sub.3 O CH.sub.3 O 1 3 (CH.sub.3).sub.2 CHCH(OH)CH.sub.2Cl CH.sub.3 O CH.sub.3 O 1 3 (CH.sub.3).sub.2 C(OH)CH.sub.2 CH.sub.2Cl CH.sub.3 O H 1 3 (CH.sub.3).sub.2 C(OH)H CH.sub.3 O CH.sub.3 O 2 2 CH.sub.2 OHCl CH.sub.3 O CH.sub.3 O 2 2 CH.sub.2 CH.sub.2 OHCl CH.sub.3 O H 2 2 CH.sub.3 CH(OH)H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 3 3 CH.sub.2 OHCl CH.sub.3 O CH.sub.3 O 3 3 (CH.sub.3).sub.2 C(OH)Cl CH.sub.3 H 3 3 (CH.sub.3 CH.sub.2).sub.2 C(OH)______________________________________
EXAMPLE 15
2-[4-(2-Tetrahydrofuroyl)piperazin-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinazoline
To 35 ml. of isoamyl alcohol were added 1.50 g. (5.47 mmole) of 4-amino-2,6-dichloro-7,8-dimethoxyquinazoline and 1.11 g. (6.02 mmole) of 1-(2-tetrahydrofuroyl)piperazine and the mixture was heated at reflux under a nitrogen atmosphere for 1.5 hours. The mixture was cooled, 20 ml. of ethyl ether was added and the resulting mixture stirred at room temperature overnight. It was then cooled in ice and the precipitated solid collected by filtration. The crude material was recrystallized once from a mixture of isopropanol, methanol and ethyl ether. The recrystallized material was dissolved in water made strongly alkaline with sodium hydroxide solution while stirring, the precipitated brownish solid collected by filtration, dried, decolorized with activated carbon and recrystallized from isopropanol/ethyl ether to obtain 0.38 g. of yellow solid, M.P. 192°-193° C.
Analysis, Percent Calc'd. for C 19 H 24 O 4 N 5 Cl: C, 54.09; H, 5.73; N, 16.60 Found: C, 53.83; H, 5.73; N, 16.58.
Mass spectrum peaks (M + /e); 421 (molecular ion), 406, 392, 378, 350, 321, 293, 280 and 266.
EXAMPLE 16
Employing the procedures of Examples 8, 9 and 10 the following compounds are similarly prepared from the appropriate starting materials.
______________________________________ ##STR55##Y.sup.1 Y.sup.2 Y.sup.3 W______________________________________H CH.sub.3 O CH.sub.3 O HCl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O CH.sub.3H n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O CH.sub.2 CH(CH.sub.3).sub.2Cl iso-C.sub.3 H.sub.7 O H CH.sub.2 (CH.sub.2).sub.4 CH.sub.3H CH.sub.3 O CH.sub.3 O CH.sub.2 CHCH.sub.2Cl CH.sub.3 O CH.sub.3 O CH.sub.2 C(CH.sub.3)CH.sub.2H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O CH.sub.2 CHCHCH.sub.3Cl C.sub.2 H.sub.5 O H CH.sub.2 C(CH.sub.3)CHCH.sub.3H n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O CH.sub.2 (CH.sub.2).sub.2 CHCH.sub.2Cl n-C.sub.3 H.sub. 7 O n-C.sub.3 H.sub.7 O CH.sub.2 CH.sub.2 OHH iso-C.sub.3 H.sub.7 O CH.sub.3 O CH.sub.2 CH.sub.2 OHCl CH.sub.3 O H CH.sub.2 CH(OH)CH.sub.3H CH.sub.3 O CH.sub.3 O CH.sub.2 C(OH)(CH.sub.3).sub.2Cl CH.sub.3 O CH.sub.3 O CH(CH.sub.3)CH(CH.sub.3)CH.sub.2 OHH C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O CH.sub.2 C(CH.sub.3).sub.2 CH.sub.2 OHCl C.sub.2 H.sub.5 O H C(CH.sub.3).sub.2 C(OH)CH.sub.3H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O cyclopropylCl n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O cyclopentylH n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O cyclohexylCl CH.sub.3 O H cyclooctylH CH.sub.3 O CH.sub.3 O 4-ClC.sub.6 H.sub.4Cl CH.sub.3 O H 2-FC.sub.6 H.sub.4H CH.sub.3 O CH.sub.3 O 4-CH.sub.3 OC.sub.6 H.sub.4 CH.sub.2Cl CH.sub.3 O H 3-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2H CH.sub.3 O CH.sub.3 O 4-HOC.sub.6 H.sub.4H CH.sub.3 O CH.sub.3 O 2-CH.sub.3 SO.sub.2 C.sub. 6 H.sub.4Cl CH.sub.3 O CH.sub.3 O 4-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.4Cl C.sub.2 H.sub.5 O H 4-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.4 CH.sub.2Cl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 4-CH.sub.3 SO.sub.2 C.sub.6 H.sub.4 CH.sub.2Cl C.sub.2 H.sub.5 O H 4-BrC.sub.6 H.sub.4 CH.sub.2Cl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 2-CH.sub.3 C.sub.6 H.sub.4 CH.sub.2Cl C.sub.2 H.sub.5 O H 3-FC.sub.6 H.sub.4 CH.sub.2Cl CH.sub.3 O H 2-fluoro-1-naphthylH CH.sub.3 O CH.sub.3 O 4-bromo-2-naphthylH CH.sub.3 O CH.sub.3 O 4-methyl-1-naphthylH CH.sub.3 O CH.sub.3 O 3-trifluoromethyl-1-naphthylCl CH.sub.3 O CH.sub.3 O 2-hydroxy-1-naphthylH CH.sub.3 O CH.sub.3 O 4-hydroxy-1-naphthylmethylCl CH.sub.3 O H 4-methoxy-2-naphthylmethylCl CH.sub.3 O CH.sub.3 O 3-fluoro-1-naphthylmethylH CH.sub.3 O CH.sub.3 O 6-methylsulfonylamino-1- naphthylmethylH CH.sub.3 O CH.sub.3 O 4-methylsulfonyl-1-naphthylH CH.sub.3 O CH.sub.3 O CH.sub.2 CCHCl CH.sub.3 O CH.sub. 3 O CH.sub.2 CCCH.sub.3Cl CH.sub.3 O CH.sub.3 O CH.sub.2 CCCH.sub.2 CH.sub.3H CH.sub.3 O CH.sub.3 O CH.sub.2 (CH.sub.2).sub.2 CCHCl CH.sub.3 O H CHOCl CH.sub.3 O H COCH.sub.3H iso-C.sub.3 H.sub.7 O iso-C.sub.3 H.sub.7 O COCH(CH.sub.3).sub.2H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O COCH.sub.2 (CH.sub.2).sub.4 CH.sub.3Cl CH.sub.3 O CH.sub.3 O COCH.sub.2 (CH.sub.2).sub.2 CH(CH.sub.3).sub.2Cl CH.sub.3 O H COCH.sub.2 CHCH.sub.2H n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O COCH.sub.2 C(CH.sub.3)CH.sub.2Cl CH.sub.3 O CH.sub.3 O COCH.sub.2 C(CH.sub.3)CHCH.sub.3Cl CH.sub.3 O H COCH.sub.2 CCHH CH.sub.3 O CH.sub.3 O COCH.sub.2 CCCH.sub.3H CH.sub.3 O CH.sub.3 O COCCCH.sub.2 CH.sub.2 CH.sub.3Cl CH.sub.3 O CH.sub.3 O cyclopropylcarbonylH CH.sub.3 O CH.sub.3 O cyclobutylcarbonylH C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O cycloheptylcarbonylH CH.sub.3 O CH.sub.3 O cyclooctylcarbonylH CH.sub.3 O CH.sub.3 O cyclopropylmethylcarbonylCl CH.sub.3 O H cyclooctylmethylcarbonylCl CH.sub.3 O H 3-thenoylH CH.sub.3 O CH.sub.3 O 5-chloro-2-thenoylH CH.sub.3 O CH.sub.3 O 4-methyl-3-thenoylCl CH.sub.3 O CH.sub.3 O 5-phenyl-2-thenoylH CH.sub.3 O CH.sub.3 O 5-ethyl-3-furoylH CH.sub.3 O CH.sub.3 O 5-phenyl-2-furoylH CH.sub.3 O CH.sub.3 O 2-pyridylcarbonylH CH.sub.3 O CH.sub.3 O 2-chloro-4-pyridylcarbonylCl CH.sub.3 O H 2-methyl-4-pyrimidinylcarbonylH CH.sub.3 O CH.sub.3 O 2-phenyl-4-pyrimidinylcarbonylH CH.sub.3 O CH.sub.3 O ##STR56##Cl CH.sub.3 O CH.sub.3 O ##STR57##Cl CH.sub.3 O H ##STR58##H CH.sub.3 O CH.sub.3 O ##STR59##H CH.sub.3 O CH.sub.3 O ##STR60##Cl CH.sub.3 O H ##STR61##Cl CH.sub.3 O CH.sub.3 O ##STR62##Cl CH.sub.3 O CH.sub.3 O ##STR63##H CH.sub.3 O CH.sub.3 O ##STR64##H CH.sub.3 O CH.sub.3 O ##STR65##Cl CH.sub.3 O H ##STR66##Cl CH.sub.3 O H 1-hydroxy-2-naphthoylH CH.sub.3 O CH.sub.3 O 4-chloro-1-naphthylmethyl- carbonylCl CH.sub.3 O H ##STR67##Cl CH.sub.3 O CH.sub.3 O ##STR68##H CH.sub.3 O CH.sub.3 O ##STR69##H CH.sub.3 O CH.sub.3 O ##STR70##Cl CH.sub.3 O H ##STR71##H CH.sub.3 O CH.sub.3 O ##STR72##Cl CH.sub.3 O CH.sub.3 O ##STR73##Cl CH.sub.3 O H ##STR74##H CH.sub.3 O CH.sub.3 O ##STR75##Cl CH.sub.3 O H ##STR76##H CH.sub.3 O CH.sub.3 O ##STR77##Cl CH.sub.3 O H CH.sub.3 OCOH CH.sub.3 O CH.sub.3 O CH.sub.3 (CH.sub.2).sub.5 CH.sub.2 OCOCl CH.sub.3 O CH.sub.3 O cyclohexyl OCOH CH.sub.3 O CH.sub.3 O HOCH.sub.2 CH.sub.2 OCOCl CH.sub.3 O H (CH.sub.3).sub.2 C(OH)CH.sub.2 CH.sub.2 OCOCl CH.sub.3 O CH.sub.3 O 4-BrC.sub.6 H.sub.4 CH.sub.2 OCOH CH.sub.3 O CH.sub.3 O 1-hydroxy-2-naphthylmethyl-OCOH CH.sub.3 O CH.sub.3 O CH.sub.2CHCH.sub.2 OCOCl CH.sub.3 O CH.sub.3 O CH.sub.2C(CH.sub.3)CH.sub.2 OCOCl CH.sub.3 O H CH.sub.3 CHC(CH.sub.3)CH.sub.2 OCOCl C.sub.2 H.sub.5 O H cyclopropyl-OCOCl n-C.sub.3 H.sub.7 O H cyclohexyl-OCOH n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O cycloheptyl-OCOCl CH.sub.3 O CH.sub.3 O cyclooctyl-OCOCl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O CH.sub.3 CH(OH)CH.sub.2 OCOH C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 2-CH.sub.3 C.sub.6 H.sub.4 CH.sub.2 OCOCl CH.sub.3 O CH.sub.3 O 3-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2 OCOCl CH.sub.3 O CH.sub.3 O 4-CH.sub.3 OC.sub.6 H.sub.4 CH.sub.2 OCOCl CH.sub.3 O H 4-HOC.sub.6 H.sub.4 CH.sub.2 OCOCl CH.sub.3 O H 3-CH.sub.3 SO.sub.2 C.sub.6 H.sub.4 CH.sub.2 OCOH CH.sub.3 O CH.sub.3 O 4-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.4 CH.sub.2 OCOH CH.sub.3 O CH.sub.3 O 4-chloro-1-naphthylmethyl-OCOCl CH.sub.3 O H 1-fluoro-2-naphthylmethyl-OCOCl CH.sub.3 O CH.sub.3 O 3-hydroxy-2-naphthylmethyl-OCOCl CH.sub.3 O CH.sub.3 O 2-methyl-1-naphthylmethyl-OCOH CH.sub.3 O CH.sub.3 O 1-methoxy-2-naphthylmethyl-OCOCl CH.sub.3 O H 4-trifluoromethyl-1-naphthyl- methyl-OCOCl CH.sub.3 O H ##STR78##Cl CH.sub.3 O CH.sub.3 O ##STR79##H CH.sub.3 O CH.sub.3 O ##STR80##Cl CH.sub.3 O CH.sub.3 O ##STR81##H CH.sub.3 O CH.sub.3 O ##STR82##Cl CH.sub.3 O CH.sub.3 O ##STR83##Cl CH.sub.3 O H ##STR84##Cl CH.sub.3 O H ##STR85##H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O ##STR86##Cl CH.sub.3 O H ##STR87##Cl C.sub.2 H.sub.5 O H ##STR88##Cl CH.sub.3 O CH.sub.3 O ##STR89##H CH.sub.3 O CH.sub.3 O ##STR90##Cl CH.sub.3 O CH.sub.3 O ##STR91##Cl CH.sub.3 O H ##STR92##H CH.sub.3 O CH.sub.3 O ##STR93##Cl CH.sub.3 O CH.sub.3 O ##STR94##Cl CH.sub.3 O H ##STR95##H CH.sub.3 O CH.sub.3 O ##STR96##______________________________________
EXAMPLE 17
A. 3-Chloro-4-methoxy-6-isothiocyanatobenzonitrile
To a solution of 27.4 g. (0.15 mole) of 6-amino-3-chloro-4-methoxybenzonitrile in 150 ml. of 1,2-dichloro-ethane at 0°-5° C. is added with stirring a mixture of 23 g. (0.2 mole) thiophosgene, 100 ml. 1,2-dichloroethane, 20 g. (0.2 mole) calcium carbonate and 200 ml. of water. After the addition the mixture is stirred for one hour at 0°-5° C., warmed to 20° C. and stirred for 6 hours at this temperature and finally at 35° C. for an hour. The reaction mixture is filtered and the organic layer separated, washed with dilute hydrochloric acid, water and dried (MgSO 4 ). The solvent is removed by evaporation and the residue used without purification in the next step.
B. 3-Chloro-4-methoxy-6-(homomorpholin-4-yl)thiocarbamidobenzonitrile
To 11.3 g. (0.05 mole) of the above residue dissolved in 65 ml. of ethyl acetate is slowly added with stirring at 0° C., a solution of 5.1 g. (0.05 mole) of homomorpholine in an equal volume of the same solvent. The resulting mixture is cooled to -25° C. and allowed to stand overnight. The precipitate is collected by filtration, washed with cold ethyl acetate and dried to obtain the desired product.
C. N-(3-Methoxy-4-chloro-6-cyanophenyl)-(homomorpholin-4-yl)-methylthioformamidate
In 200 ml. of diglyme (diethylene glycol dimethylether) is dissolved 16.3 g. (0.05 mole) of 3-chloro-4-methoxy-6-(homomorpholin-4-yl)-thiocarbamidobenzonitrile and 14.2 g. (0.1 mole) of methyl iodide and the mixture heated at reflux (60° C.) for eight hours then cooled to room temperature. The resulting mixture is filtered, the solid product washed with ether and dried to obtain the hydroiodide salt of the title compound.
The hydroiodide salt is dissolved in 150 ml. of methanol and 90 ml. of 25% ammonium hydroxide is added with stirring. The resulting mixture is stirred for two hours at 0° C., filtered and washed with ether to obtain the title compound as the free base.
D. 2-(Homomorpholin-4-yl)-4-amino-6-chloro-7-methoxyquinazoline
To a solution of 3.4 g. (0.01 mole) of the free base obtained in Part C, above, in 75 ml. of formamide is added 1.3 g. of sodium amide and the resulting solution is cooled to 0° C. and saturated with ammonia gas. The cold solution is warmed slowly over 2-3 hours to 120° C., then maintained at this temperature for 4 hours. The reaction mixture is then cooled to room temperature, 100 ml. of ice-water added, the mixture extracted with chloroform, the extracts washed with water, dried and evaporated to dryness. The crude residual product is purified by crystallization.
EXAMPLE 18
Employing one of the procedures of Examples 4, 8, 9 and 17, the following compounds are prepared from the appropriate starting materials.
__________________________________________________________________________ ##STR97##Y.sup.1 Y.sup.2 Y.sup.3 R.sup.1 R.sup.2__________________________________________________________________________H CH.sub.3 O CH.sub.3 O H HH CH.sub.3 O CH.sub.3 O H CH.sub.3Cl CH.sub.3 O CH.sub.3 O H (CH.sub.3).sub.2 CHCl CH.sub.3 O H H (CH.sub.3).sub.2 CHCH(CH.sub.3)Cl C.sub.2 H.sub.5 O H CH.sub.3 CH.sub.3H CH.sub.3 O CH.sub.3 O CH.sub.3 (CH.sub.2).sub.3 CH.sub.2 CH.sub.3 CH.sub.2Cl CH.sub.3 O CH.sub.3 O CH.sub.3 (CH.sub.2).sub.3 CH.sub.2 CH.sub.3 (CH.sub.2).sub.3 CH.sub.2Cl CH.sub.3 O CH.sub.3 O H cyclopropylCl CH.sub.3 O H CH.sub.3 cyclopentylH CH.sub.3 O CH.sub.3 O H cyclooctylH CH.sub.3 O CH.sub.3 O cyclopropyl cyclopropylCl CH.sub.3 O CH.sub.3 O cyclohexyl cyclohexylCl CH.sub.3 O H cyclohexyl cyclooctylCl CH.sub.3 O H CH.sub.2 CHCH.sub.2 CH.sub.2CHCH.sub.2H n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O CH.sub.2 CH(CH.sub.2).sub.3 CH.sub.2 CH(CH.sub.2).sub.3Cl CH.sub.3 O H CH.sub.2 C(CH.sub.3)CH.sub.2 CH.sub.2 C(CH.sub.3)CH.sub.2Cl CH.sub.3 O CH.sub.3 O CH.sub.3 CH.sub.2 CHCH.sub.2Cl CH.sub.3 O CH.sub.3 O H CH.sub.2 CHCH.sub.2H CH.sub.3 O CH.sub.3 O H (CH.sub.3).sub.2 CCHCH.sub.2H CH.sub.3 O CH.sub.3 O H CHCCH.sub.2Cl CH.sub.3 O CH.sub.3 O H CHC(CH.sub.2).sub.3Cl CH.sub.3 O H CH.sub.3 CH.sub.2 CH.sub.2 CHCCH.sub.2Cl CH.sub.3 O CH.sub.3 O cyclopropyl CH.sub.3 CCCH.sub.2Cl CH.sub.3 O CH.sub.3 O cyclohexyl CHCCH.sub.2H CH.sub.3 O CH.sub.3 O CH.sub.2 CHCH.sub.2 CHCCH.sub.2H CH.sub.3 O CH.sub.3 O CH.sub.3 (CH.sub.2).sub.4 CH.sub.2 CH.sub.2 CHCH.sub.2Cl CH.sub.3 O CH.sub.3 O cyclooctyl CH.sub.3 CHCHCH.sub.2Cl CH.sub.3 O H CH.sub.3 (CH.sub.2).sub.3 CH.sub.2 (CH.sub.3).sub.2 CCHCH.sub.2Cl CH.sub.3 O H HOCH.sub.2 CH.sub.2 HOCH.sub.2 CH.sub.2H CH.sub.3 O CH.sub.3 O H HO(CH.sub.2).sub.5Cl CH.sub.3 O CH.sub.3 O H HOCH.sub.2 CH.sub.2Cl CH.sub.3 O H HO(CH.sub.2).sub.5 HO(CH.sub.2).sub.5Cl CH.sub.3 O H CH.sub.3 HOCH.sub.2 CH.sub.2 CH.sub.2H CH.sub.3 O CH.sub.3 O (CH.sub.3).sub.2 CHCH.sub.2 CH.sub.2 HOCH.sub.2 CH.sub.2Cl CH.sub.3 O CH.sub.3 O cyclohexyl CH.sub.3 CH(OH)CH.sub.2Cl CH.sub.3 O H CH.sub.2 CHCH.sub.2 (CH.sub.3).sub.2 C(OH)CH.sub.2H CH.sub.3 O CH.sub.3 O CHCCH.sub.2 HO(CH.sub.2).sub.5H CH.sub.3 O CH.sub.3 O cyclopropyl HOCH.sub.2 CH.sub.2__________________________________________________________________________
EXAMPLE 19
A. 2-(3-Thiazolidinyl)-4-amino-7,8-dimethoxyquinazoline Hydrochloride
A mixture of 4.8 g. (0.02 mole) of 4-amino-2-chloro-7,8-dimethoxyquinazoline and 4.5 g. (0.05 mole) of thiazolidine in 50 ml. of chlorobenzene is heated at reflux for 18 hours, cooled to room temperature and the precipitate collected by filtration to give the title compound which was purified by recrystallization.
B. 2-(3-Thiazolidinyl)-4-amino-7,8-dimethoxyquinazoline S-oxide
The product obtained in Part A, 1.0 g., is converted to the free base by partitioning between dilute aqueous sodium hydroxide and methylene chloride. The organic extracts are dried and concentrated in vacuo to 100 ml. To the methylene chloride solution of free base at 0° C. is added dropwise over 15 minutes a solution of 0.60 g. of m-chloroperbenzoic acid in 25 ml. of the same solvent. After stirring for 2 hours at 0° C. the reaction mixture is washed with dilute sodium bicarbonate and water. The organic extracts are dried (NaSO 4 ) and evaporated to dryness in vacuo to obtain the title S-oxide which purified by recrystallization, if desired.
The title compound is also obtained by the procedure of Part A, above, when thiazolidine-S-oxide is employed as starting material in place of thiazolidine.
C. 2-(3-Thiazolidinyl)-4-amino-7,8-dimethoxyquinazoline S,S-Dioxide
A mixture of 9.6 g. (0.04 mole) of 4-amino-2-chloro-7,8-dimethoxyquinoline and 10.0 g. of thiazolidine S,S-dioxide in 200 ml. of chlorobenzene is heated at reflux for 24 hours, cooled to room temperature and the product collected by filtration. The crude title compound is purified, if desired, by recrystallization.
D. Employing the above procedures or those of Examples 4, 8 or 17 the following compounds are similarly obtained from the appropriate starting materials.
______________________________________ ##STR98##Y.sup.1 Y.sup.2 Y.sup.3 NR.sup.1 R.sup.2______________________________________H CH.sub.3 O CH.sub.3 O ##STR99##Cl CH.sub.3 O H ##STR100##Cl CH.sub.3 O CH.sub.3 O ##STR101##H CH.sub.3 O CH.sub.3 O ##STR102##Cl CH.sub.3 O H ##STR103##Cl CH.sub.3 O CH.sub.3 O ##STR104##H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O ##STR105##Cl n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O ##STR106##Cl CH.sub.3 O H ##STR107##H CH.sub.3 O CH.sub.3 O ##STR108##Cl CH.sub.3 CH.sub.3 O ##STR109##Cl CH.sub.3 O H ##STR110##______________________________________
EXAMPLE 20
A. 2-(3-Hydroxypyrrolidin-1-yl)-4-amino-6-chloro-7,8-dimethoxyquinazoline hydrochloride
A mixture of 4-amino-2,6-dichloro-7,8-dimethoxyquinazoline (5.48 g., 0.020 mole) and 3-pyrrolidinol (2.18 g., 0.025 mole) in 150 ml. of isoamyl alcohol is heated at reflux for five hours then cooled in ice. The precipitated product is collected by filtration and purified by recrystallization to obtain the title compound.
B. 2-[4-(2-Ethoxyethoxy)piperidin-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinazoline hydrochloride
4-Amino-2,6-dichloro-7,8-dimethoxyquinazoline (4.9 g.), 4-(2-ethoxyethoxy)piperidine (3.2 g.) and triethylamine (10 ml.) in n-butanol (400 ml.) are heated at reflux overnight under an atmosphere of nitrogen. The mixture is then cooled, evaporated in vacuo, and the residue basified (aqueous Na 2 CO 3 ) and extracted 3 times with chloroform. The combined chloroform extracts are evaporated and the residue chromatographed on neutral alumina to give the crude product which is converted to the hydrochloride salt by treatment with hydrogen chloride in ethanol to afford the title compound.
C. By the above procedures the following compounds are similarly provided from the appropriate starting materials in each case.
______________________________________ ##STR111##Y.sup.1 Y.sup.2 Y.sup.3 NR.sup.1 R.sup.2______________________________________H CH.sub.3 O CH.sub.3 O ##STR112##Cl CH.sub.3 O CH.sub.3 O ##STR113##Cl CH.sub.3 O CH.sub.3 O ##STR114##H CH.sub.3 O CH.sub.3 O ##STR115##H CH.sub.3 O CH.sub.3 O ##STR116##H CH.sub. 3 O CH.sub.3 O ##STR117##Cl CH.sub.3 O H ##STR118##Cl CH.sub.3 O H ##STR119##Cl CH.sub.3 O H ##STR120##Cl CH.sub.3 O H ##STR121##Cl CH.sub.3 O H ##STR122##Cl CH.sub.3 O H ##STR123##Cl CH.sub.3 O H ##STR124##H CH.sub.3 O CH.sub.3 O ##STR125##H CH.sub.3 O CH.sub.3 O ##STR126##H CH.sub.3 O CH.sub.3 O ##STR127##Cl CH.sub.3 O CH.sub.3 O ##STR128##Cl CH.sub.3 O CH.sub.3 O ##STR129##Cl CH.sub.3 O CH.sub.3 O ##STR130##Cl CH.sub. 3 O H ##STR131##Cl CH.sub.3 O H ##STR132##H CH.sub.3 O CH.sub.3 O ##STR133##Cl CH.sub.3 O H ##STR134##Cl CH.sub.3 O H ##STR135##______________________________________
EXAMPLE 21
A. 2-(Octamethyleneimin-1-yl)-4-amino-7,8-dimethoxyquinazoline hydrochloride
To 500 ml. of isoamyl alcohol is added 23.9 g. (0.10 mole) 4-amino-2-chloro-7,8-dimethoxyquinazoline and 14.0 g. (0.11 mole) octamethyleneimine and the mixture is heated at reflux for 3.5 hours. After cooling, the precipitated solid is collected, washed with ether and dried to obtain the title compound.
B. By employing the above procedure with the appropriate starting materials in each case the following compounds are similarly provided.
______________________________________ ##STR136##Y.sup.1 Y.sup.2 Y.sup.3 2 p + n______________________________________H CH.sub.3 O CH.sub.3 O 4Cl CH.sub.3 O CH.sub.3 O 5H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 6Cl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 7H n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O 8Cl iso-C.sub.3 H.sub.7 O H 9Cl CH.sub.3 O H 4Cl CH.sub.3 O H 5Cl CH.sub.3 O CH.sub.3 O 4H CH.sub.3 O CH.sub.3 O 5______________________________________
EXAMPLE 22
2-(3-Methylpiperidin-1-yl)-4-amino-7,8-dimethoxyquinazoline
Equimolar amounts (0.10 mole) of 7,8-dimethoxy-2,4-(1H,3H)-quinazolinedione and phosphorous oxychloride are stirred at room temperature overnight and the volatiles evaporated in vacuo to afford a residue of 2-chloro-7,8-dimethoxy-4(3H)-quinazolineone which is purified by washing with aqueous sodium bicarbonate, extraction with chloroform and evaporation of solvent. To the residue is added a solution of 0.10 mole of 3-methylpiperadine in 300 ml. of isoamyl alcohol and the mixture heated at reflux for three hours, the solvent is then evaporated in vacuo to afford 2-(3-methylpiperidin-1-yl)-7,8-dimethoxy-4(3H)-quinazolineone hydrochloride. To this is added 150 ml. of phosphorous oxychloride and the resulting mixture is heated at reflux for two hours. The liquids are evaporated to give a residue of 2-(3-methylpiperidin-1-yl)-4-chloro-7,8-dimethoxyquinazoline hydrochloride. The product is dissolved in dilute aqueous sodium bicarbonate, extracted with chloroform, dried (Na 2 SO 4 ) and the solvent evaporated.
The above product is dissolved in 350 ml. of tetrahydrofuran and a solution of anhydrous ammonia (5.3 g.) in the same solvent is added. The mixture is stirred at room temperature for 24 hours, the precipitate collected by filtration and purified by recrystallization to obtain the title compound.
EXAMPLE 23
2-(3-n-Hexylpyrrolidin-1-yl)-4-amino-6-chloro-7,8-dimethoxyquinazoline
To 12 grams of 6-chloro-7,8-dimethoxy-2,4-(1H,3H)-quinazolinedione in 200 ml. of pyridine is added 30 g. of phosphorous pentasulfide and the mixture is refluxed with continuous stirring for five hours. The solvent is evaporated in vacuo and the residue decomposed with hot water. The solid material is filtered to obtain 6-chloro-7,8-dimethoxy-2,4-(1H,3H)-quinazolinedithione.
To 0.1 mole of 6-chloro-7,8-dimethoxy-2,4-(1H,3H)-quinazolinedithione in 220 ml. 1 N potassium hydroxide solution and 100 ml. methanol, is added slowly with stirring, 0.22 mole of methyl iodide. The mixture is heated on a steam bath for 2 hours, cooled, and the resulting precipitate is filtered from the mixture. The product is 6-chloro-2,4-dimethylmercapto-7,8-dimethoxyquinazoline.
To 0.1 mole of 6-chloro-2,4-dimethylmercapto-7,8-dimethoxyquinazoline in 200 ml. of tetrahydrofuan is added a solution of 0.1 mole of anhydrous ammonia in tetrahydrofuran. The mixture is stirred at room temperature for 18 hours and the precipitate which forms is collected and recrystallized from dimethylformamide/water to yield 2-methylmercapto-4-amino-6-chloro-7,8-dimethoxyquinazoline.
A mixture of 0.1 mole of 2-methylmercapto-4-amino-6-chloro-7,8-dimethoxyquinazoline and 0.12 mole of 3-n-hexylpyrrolidine in isoamyl alcohol is heated at reflux for 16 hours, cooled, washed with water and the organic phase is concentrated in vacuo. Hexane is slowly added to the residue and the solid title compound is collected and purified, if desired by silica gel column chromatography.
EXAMPLE 24
2-[4-(2,3-Dihydro-4H-benzopyran-2-carbonyl)-piperazin-1-yl]-4-amino-6-chloro-7-methoxyquinazoline hydrochloride
To 0.10 mole of 2-(piperazin-1-yl)-4-amino-6-chloro-7-methoxyquinazoline in 300 ml. of methanol is added with vigorous stirring, 0.10 mole of 2,3-dihydro-4H-benzopyran-2-carboxylic acid chloride. After the addition is complete, the mixture is stirred for three hours at room temperature and the precipitated title compound is collected by filtration.
EXAMPLE 25
2-Diethylamino-4-amino-6-chloro-7-methoxyquinazoline
To 1.0 mole of 2,5-dichloro-4-methoxybenzonitrile in dimethylformamide (300 ml.) is added 0.5 mole of N,N-diethylguanidine and the mixture is heated at 150° C. for 12 hours. The solution is concentrated in vacuo to a small volume and poured into ice-water. The precipitated solid is collected by filtration and the crude product purified by silica gel column chromatography.
When 2-amino-5-chloro-4-methoxybenzontrile or 2-amidino-5-chloro-4-methoxyaniline is employed in the above reaction in place of 2,5-dichloro-4-methoxybenzonitrile the same compound is obtained.
EXAMPLE 26
2-(N-methyl-N-cyclohexylamino)-4-amino-6-chloro-7,8-dimethoxyquinazoline
A. To 5 liters of ethanol containing 0.2 mole of sodium ethoxide is added slowly with stirring 0.1 mole each of phenol and 2,4,6-trichloro-7,8-dimethoxyquinazoline. The mixture is heated to boiling then allowed to stand at room temperature overnight, poured into ice-water, stirred 15 minutes and the precipitate collected by filtration. The cake is washed with water, then cold ethanol, dried and recrystallized from ethanol/hexane to obtain 2,6-dichloro-7,8-dimethoxy-4-ethoxyquinazoline.
B. A mixture of 0.1 mole of the above product and 0.11 mole of N-methylcyclohexylamine in 350 ml. of ethanol is heated at reflux for three hours, cooled and poured into dilute aqueous sodium carbonate solution. The precipitated product is extracted with chloroform and the extracts evaporated to dryness to obtain 2-(N-methyl-N-chlorohexylamino)-4-ethoxy-7,8-dimethoxyquinazoline suitable for use in the next step.
C. To 0.1 mole of the product of Part B in 300 ml. of tetrahydrofuran, anhydrous ammonia is passed through until the mixture has absorbed 0.11 mole. The mixture is then stirred for 24 hours at room temperature, then heated at reflux for two hours and cooled in ice. The precipitated solid is collected by filtration to afford the title compound which may be purified, if desired, by recrystallization or by chromatography.
D. When 2,6-dichloro-7,8-dimethoxy-4-methyl-thioquinazoline (prepared from the corresponding 2,4,6-trichloro- compound and methylmercaptan in the presence of sodium ethoxide by the procedure of Curd et al., J. Chem. Soc., 775-783 (1947) for 2-chloro-4-methylthioquinazoline) is used in place of 2,6-dichloro-7,8-dimethoxy-4-ethoxyquinazoline in Part B, above, and the resulting product carried through the above procedures the title compound is similarly obtained.
EXAMPLE 27
2-(Morpholin-4-yl)-4-amino-7,8-dimethoxyquinazoline hydrochloride
To 500 ml. of methylethylketone is added 0.1 mole of 4-amino-2-chloro-7,8-dimethoxyquinazoline and 0.12 mole of morpholine and the mixture is refluxed overnight. After cooling in ice-water the solid precipitated is collected by filtration, washed with ether and air dried to obtain the title compound.
When the appropriate starting materials are employed in each case in the above procedure or any of the procedures of Examples 17, or 22-26, the following compounds are likewise obtained.
______________________________________ ##STR137##Y.sup.1 Y.sup.2 Y.sup.3 m n______________________________________H CH.sub.3 O CH.sub.3 O 2 3Cl C.sub.2 H.sub.5 O CH.sub.3 O 2 2Cl n-C.sub.3 H.sub.7 O H 3 3Cl CH.sub.3 O H 2 2Cl CH.sub.3 O H 2 3Cl CH.sub.3 O CH.sub.3 O 2 3H CH.sub.3 O CH.sub.3 O 3 3Cl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 3 3______________________________________
EXAMPLE 28 ##STR138##
To a stirred solution of 1.78 g. (0.01 mole) 3,4-dimethoxy-2-aminobenzonitrile in 30 ml. of N,N-dimethylformamide is added 2.88 g. (0.01 mole) ethyl 4-(2-furoyl)piperazin-1-ylformimidate hydrochloride followed by 855 mg. (0.02 mole) of a 56.1% dispersion of sodium hydride in mineral oil. The reaction mixture is stirred at ambient temperature for 30 minutes, and then it is heated to ca. 100° C. and maintained at that temperature for 12 hours. The reaction mixture is cooled to ambient temperature, diluted with an excess of water, and then extracted with chloroform. The chloroform extract is washed several times with water, dried using anhydrous magnesium sulfate, and then evaporated to dryness in vacuo. This affords crude 7,8-dimethoxy-4-amino-2-[4-(2-furoyl)piperazin-1-yl]quinazoline, which is purified further by recrystallization from aqueous ethanol.
B. The above procedure is repeated, except that the ethyl 4-(2-furoyl)piperazin-1-ylformimidate hydrochloride used therein is replaced by an equimolar amount of:
ethyl 4-allylpiperazin-1-ylformimidate methanesulfonate,
methyl 4-benzoylpiperazin-1-ylformimidate hydrochloride,
isopropyl 4-(3-furoyl)piperazin-1-ylformimidate hydrochloride,
methyl 4-(allyloxycarbonyl)piperazin-1-ylthioformimidate hydroiodide,
ethyl 4-(2-methylprop-2-enyloxycarbonyl)piperazin-1-ylthioformimidate hydrobromide and
ethyl-4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-ylthioformimidate hydrobromide, respectively.
This affords:
7,8-dimethoxy-4-amino-2-(4-allylpiperazin-1-yl)quinazoline,
7,8-dimethoxy-4-amino-2-(4-benzoylpiperazin-1-yl)quinazoline,
7,8-dimethoxy-4-amino-2-[4-(3-furoyl)piperazin-1-yl]quinazoline,
7,8-dimethoxy-4-amino-2-[4-(allyloxycarbonyl)piperazine-1-yl]quinazoline,
7,8-dimethoxy-4-amino-2-[4-(2-methylprop-2-enyloxycarbonyl)piperazin-1-yl]quinazoline and
7,8-dimethoxy-4-amino-2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]quinazoline, respectively,
C. The procedure of Part A is repeated, except that the 3,4-dimethoxy-2-aminobenzonitrile used therein is replaced by an equimolar amount of:
5-chloro-3,4-dimethoxy-2-aminobenzonitrile,
5chloro-3,4-diethoxy-2-aminobenzonitrile,
5-chloro-4-methoxy-2-aminobenzonitrile, or
5-chloro-4-isopropoxy-2-aminobenzonitrile, to provide the following compounds, respectively,
______________________________________ ##STR139## Y.sup.2 Y.sup.3______________________________________ CH.sub.3 O CH.sub.3 O C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O CH.sub.3 O H (CH.sub.3).sub.2 CHO H______________________________________
EXAMPLE 29
5-Chloro-4-methoxy-2-aminobenzamidine hydrochloride prepared by the procedure of U.S. Pat. No. 3,935,213 for analogous compounds (0.01 mole) and an equimolar amount of 1-cyano-4-ethoxycarbonylpiperazine also provided in the same reference, are dissolved in 50 ml. of anhydrous ethanol and stirred overnight at ambient temperature. A 5 ml. aliquot of triethylamine is added and the mixture is heated at reflux for 12 hours. The solvent is evaporated to provide 4-amino-6-chloro-7-methoxy-2-[4-ethoxycarbonylpiperazin-1-yl]quinazoline as the hydrochloride salt.
EXAMPLE 30
A stirred solution of 24 ml. of concentrated sulfuric acid dissolved in an equal volume of water was cooled to 10°-12° C. and 0.015 mole of methallyl 4-(4-amino-6-chloro-7,8-dimethoxyquinazolin-2-yl)piperazine-1-carboxylate is added in small portions with stirring. The addition is carried out at a rate sufficient to keep the reaction temperature below 20° C. The resulting mixture is stirred for 15 minutes at 15°-20° C., then for two hours at 10°-15° C. The reaction mixture is diluted with 150 ml. of ice-water and adjusted to pH 10 with sodium hydroxide while maintaining the temperature below 12° C. After extraction with chloroform, the combined extracts are washed with water and dried over anhydrous sodium sulfate. The solvent is evaporated in vacuo and the residue recrystallized to afford 2-methyl-2-hydroxypropyl 4-(4-amino-6-chloro-7,8-dimethoxyquinazolin-2-yl)piperazine-1-carboxylate.
EXAMPLE 31
2-[4-(3-hydroxypropyl)homopiperazin-1-yl]-4-amino-7,8-dimethoxyquinazoline hydrochloride
A. 2-Chloro-4-amino-7,8-dimethoxyquinazoline, 17 g. and N-formylhomopiperazine, 18.2 g. are added to 170 ml. n-butanol and the mixture is refluxed for three hours, cooled and the precipitated solid collected by filtration. The precipitate is washed with a small amount of ethanol and air-dried. A mixture of 13 g. of this solid and 80 ml. of 9% (by weight) hydrochloric acid are heated at reflux for 60 minutes, then allowed to cool and the precipitate of 2-homopiperazino-4-amino-7,8-dimethoxyquinazoline is collected and purified, if desired, by recrystallization.
B. A mixture of 4 g. of triethylamine, 3.0 g. of 2-homopiperazino-4-amino-7,8-dimethoxyquinazoline, 4.5 g. of 3-bromo-1-propanol and 50 ml. of diethyleneglycol dimethylether is heated at 100°-120° C. with stirring for 16 hours. The reaction mixture is concentrated in vacuo and the residue made alkaline by addition of sodium hydroxide solution. The mixture is extracted with chloroform, the extracts washed with water, dried with potassium carbonate and filtered. The filtrate is concentrated, the residue taken up in isopropanol and a solution of hydrogen chloride in isopropanol added until precipitation is complete. The title compound is collected by filtration and dried.
C. When an equivalent amount of 1,3-propandiol monotosylate or 1,3-propandiol monomethylsulfonate are employed in place of 3-bromo-1-propanol in Part B, above, the results are substantially the same.
EXAMPLE 32
Employing the appropriate starting materials in each case the following compounds are prepared by the procedures of Examples 31 according to the equation ##STR140##
Where a is 1 or m; m and n are 2 or 3 and Q is a leaving group such as Br, Cl, p-toluenesulfonyloxy or methanesulfonyloxy.
______________________________________Y.sup.1Y.sup.2 Y.sup.3 a n R.sup.3______________________________________Cl CH.sub.3 O H 1 2 CH.sub.3Cl CH.sub.3 O CH.sub.3 O 1 3 CH.sub.3 (CH.sub.2).sub.3H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 2 2 (CH.sub.3).sub.2 CH(CH.sub.2).sub.3Cl C.sub.2 H.sub.5 O H 2 2 CH.sub.3 (CH.sub.2).sub.5Cl n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O 2 2 CH.sub.2CHCH.sub.2H i-C.sub.3 H.sub.7 O i-C.sub.3 H.sub.7 O 3 2 CH.sub.3 CHCHCH.sub.2Cl CH.sub.3 O H 3 2 (CH.sub.3).sub.2 CCHCH.sub.2Cl CH.sub.3 O CH.sub.3 O 3 3 HCCCH.sub.2H CH.sub.3 O CH.sub.3 O 3 3 CH.sub.3 CCCH.sub.2Cl CH.sub.3 O CH.sub.3 O 1 2 HOCH.sub.2 CH.sub.2Cl CH.sub.3 O H 2 2 (CH.sub.3).sub.2 C(OH)CH.sub.2H CH.sub.3 O CH.sub.3 O 1 2 (CH.sub.3).sub.2 C(OH)CH.sub.2 CH.sub.2Cl CH.sub.3 O H 2 2 cyclopropylCl CH.sub.3 O CH.sub.3 O 2 3 cyclopentylH CH.sub.3 O CH.sub.3 O 3 3 cyclohexylCl CH.sub.3 O H 2 2 cycloheptylCl CH.sub.3 O CH.sub.3 O 2 2 cyclooctylH CH.sub.3 O CH.sub.3 O 2 3 1-naphthylH CH.sub.3 O CH.sub.3 O 2 2 2-naphthylmethylH CH.sub.3 O CH.sub.3 O 2 2 4-HOC.sub.6 H.sub.5H CH.sub.3 O CH.sub.3 O 2 2 4-BrC.sub.6 H.sub.4 CH.sub.2H CH.sub.3 O CH.sub.3 O 1 2 3-CH.sub.3 C.sub.6 H.sub.4 CH.sub.2Cl CH.sub.3 O CH.sub.3 O 1 3 ##STR141##H CH.sub.3 O CH.sub.3 O 2 3 ##STR142##H CH.sub.3 O CH.sub.3 O 2 2 ##STR143##H CH.sub.3 O CH.sub.3 O 1 2 ##STR144##______________________________________
EXAMPLE 33
A. 2,3-Dimethoxyaniline obtained by the method of Gibson et al., J. Chem. Soc., 111, 79 (1917), is converted to 2,3-dimethoxy isothiocyanate according to the procedure of Dyson et al, J. Chem. Soc., 436 (1927) for analogous compounds.
A solution of 2,3-dimethoxy isothiocyanate (32.1 g., 0.164 mole) in 100 ml. of absolute ethanol is added to a stirred solution of 1-(2-furoyl)piperazine (29.6 g., 0.164 mole) prepared by the method of Desai et al., Org. Prep. Proced. Int., 8, 85 (1976) in 350 ml. of absolute ethanol and the mixture heated at reflux for 2.5 hours. The crude 4-(2-furoyl)piperazine-1-(N-2,3-dimethoxyphenyl)carbothioamide is isolated by evaporation of solvent in vacuo and purified by recrystallization.
B. To a suspension of 22.0 g. (0.0586 mole) of the product obtained in Part A, above, in 400 ml. of methanol is added methyl iodide 8.32 g. (0.0586 mole). The mixture is stirred at reflux for 2.5 hours, cooled to 20° C., 18.7 g. of cyanamide (0.445 mole) is added and the resulting mixture is heated at reflux for an additional 16 hours. The solvent is evaporated in vacuo and the residue made strongly basic with 4.0 N sodium hydroxide. The alkaline mixture is extracted with chloroform, the extracts washed first with water then with saturated brine and dried over anhydrous magnesium sulfate. The dried extract is concentrated to dryness under reduced pressure and the residue crystallized to afford 4-(2-furoyl)piperazine-1-[N-cyano-N'-(2,3-dimethoxyphenyl)]carboxamidine.
C. Following the procedure of Part A, above, but employing an equimolar amount of 2,3-dimethoxyphenyl isocyanate in place of 2,3-dimethoxyphenyl isothiocyanate, there is obtained N-(2,3-dimethoxyphenyl)-4-(2-furoyl)-1-piperazinecarboxamide. Reaction of this carboxamidee with methyl fluorosulfonate and then with cyanamide according to the procedure of Part B, above, provides the same product obtained in Part B.
D. By employing other amines of formula R 1 R 2 NH, where R 1 and R 2 are as shown in Examples 18 and 19 or taken together R 1 and R 2 are ##STR145## as in Examples 10 and 16 or ##STR146## as in Example 14, in the procedures of Parts A and B or Part C, above, provides compounds of the following formula in like manner. ##STR147## Y 1 , Y 2 , Y 3 have the values shown in Examples 10, 14, 16, 18 and 19.
EXAMPLE 34
4-Amino-7,8-dimethoxy-2-[4-(2-furoyl)piperazin-1-yl]quinazoline hydrochloride
A. To 10 ml. of phosphorus oxychloride is added with stirring 0.31 g. of phosphorus pentachloride (1.48 mmoles) followed by 0.54 g. (1.48 mmoles) of 4-(2-furoyl)piperazine-1[N-cyano-N'-(2,3-dimethoxyphenyl)]carboxamidine of Example 33, Part B. The reaction mixture is heated at 95°-98° C. for 2.5 hours, cooled to 30° C. and excess phosphorus oxychloride is evaporated in vacuo and the residue is triturated with ice water. The aqueous phase is filtered and the filtrate concentrated in vacuo to provide the crude product which is purified by crystallization or column chromatography.
B. When the phosphorus pentachloride used above is replaced by an equimolar amount of hydrogen chloride gas, phosphorus pentabromide, trifluoroacetic acid, ZnCl 2 , FeCl 3 , AlCl 3 or AlBr 3 and the reaction carried out at 70°-100° C. for one to three hours the results are substantially the same as in Part A.
EXAMPLE 35
Tablets
A tablet base is prepared by blending the following ingredients in the proportion by weight indicated:
______________________________________Sucrose, U.S.P. 80.3Tapioca starch 13.2Magnesium stearate 6.5______________________________________
Into this base is blended sufficient 2-[4-(2-furoyl)-1-piperazinyl]-4-amino-6-chloro-7-methoxyquinazoline hydrochloride to provide tablets containing 0.5, 1.0, 10, 100 and 250 mg. of active ingredient.
EXAMPLE 26
Capsules
A blend is prepared containing the following ingredients:
______________________________________Calcium carbonate, U.S.P. 17.6Dicalcium phosphate 18.8Magnesium trisilicate, U.S.P. 5.2Lactose, U.S.P. 5.2Potato starch 5.2Magnesium stearate A 0.8Magnesium stearate B 0.35______________________________________
To this blend is added sufficient 2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]-4-amino-6-chloro-7-methoxyquinazoline to provide formulations containing 0.5, 1.0, 5, 10, 100, 250 and 500 mg. of active ingredient, and the formulations are filled into hard gelatin capsules of a suitable size.
EXAMPLE 37
Injectable Preparation
2-[4-(2-furoyl-1-piperazinyl]-4-amino-6,7-dimethoxyquinazoline hydrochloride is intimately mixed and ground with 2500 g. of sodium ascorbate. The ground dry mixture is filled into vials, sterilized with ethylene oxide and the vials sterile stoppered. For intravenous administration sufficient water is added to the vials to form a solution containing 10 mg. of active ingredients per milliliter.
EXAMPLE 38
Solution
A solution of 2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinazoline or a pharmaceutically acceptable salt thereof is prepared with the following composition:
______________________________________Effective ingredient 30.22 g.Magnesium chloride hexahydrate 12.36 g.Monoethanolamine 8.85 ml.Propylene glycol 376 g.Water 94 ml.______________________________________
The solution has a concentration of 50 mg./ml. and is suitable for parenteral and especially for intramuscular administration.
PREPARATION A
4-Acetoxy-3-methoxybenzaldehyde (IV)
Triethylamine (2.8 liters, 20.1 moles) was added dropwise to a solution of vanillin (2.00 kg., 13.15 moles) and acetic anhydride (2.6 liters, 27.5 moles) in methylene chloride (11.3 liters) maintaining temperature below 25° C. After adding 4-dimethylaminopyridine (20 g.) the solution was stirred at room temperature for 30 minutes. The reaction mixture was washed twice with water, followed by 20% (w/w) hydrochloric acid and brine. The organic layer was dried over sodium sulfate and concentrated in vacuo to 8 liters. Hexane (15 liters) was added slowly while removing remaining methylene chloride. After cooling, 2.45 kg. (96% yield) product was filtered off. Recrystallization of a small sample from anhydrous ether gave the acetate as fine yellow needles, M.P. 76°-78° C.
PREPARATION B
4-Acetoxy-3-methoxy-2-nitrobenzaldehyde (V)
Over a period of 1.5 hours 4-acetoxy-3-methoxybenzaldehyde (1120 g., 5.77 moles) was added in small portions to 4 liters of red fuming nitric acid cooled to 0° C. After allowing to stir for one hour below 5° C., the reaction mixture was added to large amount of ice-water and stirred an additional hour. The resulting yellow product (1130 g., 82% yield) was filtered and washed three times with water, and was sufficiently pure for use directly in the next step. Recrystallization from ether/cyclohexane furnished the pure nitroaldehyde, M.P. 84°-86° C.
PREPARATION C
4-Hydroxy-3-methoxy-2-nitrobenzaldehyde (VI)
4-Acetoxy-3-methoxy-2-nitrobenzaldehyde (1120 g., 4.72 moles) was added portionwise to a freshly prepared 33% (w/w) NaOH solution (4.5 liters). The resulting slurry was heated on steam bath at 75° C. for 10 minutes after which it was diluted with 5 liters of water. The reaction mixture was acidified with 6.4 liters of 6 N hydrochloric acid while cooling, and the resulting product (794 g., 85% yield) was filtered and washed with water. Recrystallization from ether/cyclohexane gave the desired product as light yellow solid, M.P. 136°-137° C.
PREPARATION D
i. 3,4-Dimethoxy-2-nitrobenzaldehyde (VII)
Anhydrous sodium carbonate (957 g., 9.03 moles), toluene (5 liters), 4-hydroxy-3-methoxy-2-nitrobenzaldehyde (1424 g., 7.22 moles) and dimethyl sulfate (810 ml., 8.67 moles) were refluxed for 4 hours. Toluene was removed in vacuo and the residual solid dissolved in 5 liters of ethyl acetate and 3 liters of water. The organic layer was separated, washed with 2 liters of 1 N NaOH and 6 liters of brine, decolorized with charcoal, dried over magnesium sulfate and filtered. Hexane (7.6 liters) was added slowly. After cooling in an ice bath, 1527 g. product was obtained by filtration. The crude material was recrystallized from ethanol to yield 1187 g. (78%) of the title compound as a pale yellow solid, 60°-62° C.
ii. By employing diethyl sulfate in place of dimethyl sulfate in the above procedure, 4-ethoxy-3-methoxy-2-nitrobenzaldehyde is similarly obtained.
iii. When n-propyl bromide is employed as the alkylating agent the corresponding 4-n-propyloxy compound is provided.
PREPARATION E
3,4-Dimethoxy-2 -nitro-benzoic acid (VIII)
A solution of 823 g. potassium permanganate in about 8.5 liters of H 2 O was gradually added to a refluxing solution of 3,4-dimethoxy-2-nitrobenzaldehyde (550 g., 2.60 moles) in 5.6 liters of acetone. The reaction mixture was refluxed for four more hours, then filtered through diatomaceous earth while hot and the filter cake washed with hot water. The acetone was removed in vacuo and a small amount of unreacted solid was filtered off. The aqueous solution was acidified with 2 N hydrochloric acid (1.8 liters) to yield 505 g. (85% ) of the essentially pure title compound. Recrystallization from water afforded colorless crystals, M.P. 200°-202° C.
PREPARATION F
3,4-Dimethoxyanthranilic acid (IXa, R=CH 3 )
A solution of 3,4-dimethoxy-2-nitro benzoic acid (1011 g., 4.45 moles) in 14 liters of 1.3 N ammonium hydroxide was reduced at 60 psi in presence of 60 grams of palladium on barium carbonate. Hydrogen uptake ceased after four hours. The reaction mixture was filtered through diatomaceous earth and acidified with glacial acetic acid (1.2 liters) to yield 685 grams (78%) of the anthranilic acid, M.P. 183°-184° C.
PREPARATION G
4-Methoxy anthranilic acid (XXII)
i. 4-Cyano-3-nitroanisole (XIX)
A saturated solution of sodium nitrite (33.5 g., 0.485 mole) was added dropwise to a cooled solution of 4-methoxy-2-nitroaniline (68.0 g., 0.404 mole) in 300 ml. water and 94 ml. concentrated hydrochloric acid, while maintaining the temperature at 0° C. and the pH at 6 by addition of sodium carbonate.
The cold solution of diazonium salt was added carefully through a jacketed dropping funnel to a hot solution of cuprous cyanide (36.2 g., 0.404 mole) and potassium cyanide (42.1 g., 0.646 mole) in 500 ml. water, with vigorous stirring and intermittent heating on a steambath. The stirred yellow suspension was heated an additional fifteen minutes. The solid was filtered, dried and dissolved in ethyl acetate, discarding the undissolved inorganic salts. After decolorization with charcoal, concentration of the ethyl acetate solution yielded 55.1 g. (71%) of bright yellow-orange crystals, M.P. 135°-7° C.
Analysis, Percent Calc'd for C 8 H 6 N 2 O 3 : C, 53.93; H, 3.39; N, 15.73 Found: C, 53.92; H, 3.47; N, 15.85.
ii. 4-Methoxy-2-nitrobenzoic acid (XXI)
4-Cyano-3-nitroanisole (52.3 g., 0.294 mole) was slowly added to a cooled solution of 53 ml. each of acetic acid, water and sulfuric acid. The solution was refluxed for 5 hours, and then diluted with 160 ml. water. After cooling, the resulting solid was filtered and dissolved in 10% sodium hydroxide solution. After decolorization with charcoal the solution was acidified with 6 N HCl, cooled and the yellow product (51.0 g., 88% yield) was filtered. An analytical sample was recrystallized from methanol/water, M.P. 196°-7° C.
Analysis, Percent Calc'd. for C 8 H 7 NO 5 : C, 48.74; H, 3.58; N, 7.11 Found: C, 48.37; H, 3.57; N, 7.03.
iii. 4-Methoxy anthranilic acid (XXII)
A solution of 4-methoxy-2-nitrobenzoic acid (19.3 g., 97.9 mmole) in 200 ml. 1 N NH 4 OH was reduced overnight in presence of 5% Pd/BaCO 3 . The reaction mixture was filtered and acidified with acetic acid to yield 15.8 g. (96%) of the anthranilic acid, M.P. 186°-188° C.
iv. Employing 4-ethoxy-2-nitroaniline or the corresponding 4-n-propoxy- or 4-isopropoxy- compounds as starting material in the above procedures the following products are similarly obtained. ##STR148## where Y 2 is ethoxy, n-propoxy or isopropoxy.
PREPARATION H
i. Methyl-3,4-dimethoxyanthranilate
Hydrogen chloride was passed into a solution of 3,4-dimethoxyanthranilic acid (100 g., 0.51 mole) in 1.5 liters methanol for 40 minutes. The reaction mixture was refluxed for 4 days while introducing hydrogen chloride gas intermittently. The solvent was removed in vacuo, and the residual white solid was dissolved in 500 ml. water, cooled and basified to pH 10 with sodium hydroxide solution. After cooling for an additional hour, the cream color product (87.0 g., 82% yield) was filtered. Recrystallization from methanol furnished pure product, M.P. 66°-67° C.
Analysis, Percent Calc'd. for C 10 H 13 NO 4 : C, 56.86; H, 6.20; N, 6.63 Found: C, 56.56; H, 6.15; N, 6.66.
ii. Methyl-4-methoxyanthranilate
Esterification of 4-methoxy anthranilic acid as described above afforded methyl-4-methoxyanthranilate, M.P. 77°-79° C., in 77% yield.
PREPARATION I
i. 5-Chloro-3,4-dimethoxyanthranilic acid (IXb, R=CH 3 )
Sulfuryl chloride (19.3 ml., 0.24 mole) was added dropwise to a cooled solution of methyl 3,4-dimethoxyanthranilate (42.2 g., 0.20 mole) in 400 ml. chloroform at 0° C. (The sulfur dioxide produced was passed through a water trap). After stirring 30 minutes at ambient temperature the solution was refluxed for 2 hours. The black solution was treated with charcoal and the solvent was evaporated. The 1 H-NMR spectrum indicated that the black, oily residue was largely the desired intermediate ester. The crude methyl ester was saponified with 400 ml. 5% (w/v) sodium hydroxide on a steam bath for one hour. After cooling, the basic suspension was acidified with acetic acid to precipitate a brown solid which was filtered and recrystallized from carbon tetrachloride to afford light-brown crystalline product (29.0 g., 63.1% yield), M.P. 140°-2° C. [Reported M.P. 142°-3° C., J. Chem. Soc., 4310-4, 1964].
Analysis, Percent Calc'd. for C 9 H 10 ClNO 4 : C, 46.66; H, 4.35; N, 6.05 Found: C, 46.45; H, 4.45; N, 5.90.
ii. 5-chloro-4-methoxyanthranilic acid (IXc, R=CH 3 )
Treatment of methyl-4-methoxyanthranilate with sulfuryl chloride as described above afforded methyl-4-methoxy-5-chloroanthranilate, M.P., 197°-200° C. in 90% yield.
Saponification of methyl-4-methoxy-5-chloro anthranilate yielded 5-chloro-4-methoxyanthranilic acid in 64% yield, M.P., 210°-3° C.
Analysis, Percent Calc'd for C 8 H 8 ClNO 3 ; C, 47.66; H, 4.00; N, 6.95 Found: C, 48.00; H, 4.11; N, 6.94.
When methyl 4-ethoxyanthranilate or methyl 4-n-propyloxyanthranilate are carried through the above procedure 5-chloro-4-ethoxyanthranilic acid and 5-chloro-4-n-propyloxyanthranilic acid are obtained in like manner.
PREPARATION J
When ethyl vanillin (3-ethoxy-4-hydroxybenzaldehyde) or propyl vanillin, (4-hydroxy-3n-propyloxybenzaldehyde) are employed as starting material in the procedure of Preparation A in place of vanillin and the resulting products carried in turn, through the procedures of Preparation B-F and optionally chlorination by the procedures of Preparations H and I, the corresponding compounds of the following formula are similarly obtained.
______________________________________ ##STR149##Y.sup.1 Y.sup.2 Y.sup.3 Y.sup.1 Y.sup.2 Y.sup.3______________________________________H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O Cl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 OH n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O Cl n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 OH CH.sub.3 O C.sub.2 H.sub.5 O Cl CH.sub.3 O C.sub.2 H.sub.5 OH n-C.sub.3 H.sub.7 O CH.sub.3 O Cl C.sub.2 H.sub.5 O CH.sub.3 OH C.sub.2 H.sub.5 O CH.sub.3 O Cl n-C.sub.3 H.sub.7 O CH.sub.3 OH n-C.sub.3 H.sub.7 O C.sub.2 H.sub.5 O Cl n-C.sub.3 H.sub.7 O C.sub.2 H.sub.5 O______________________________________
PREPARATION K
3-(m-Trifluoromethylphenyl)piperidine
i. N-Benzyl-3-hydroxy-3-(m-trifluoromethylphenyl)piperidine
Under anhydrous conditions, to a mixture of 11 g. of magnesium in 15 ml. of ethyl ether an iodine crystal is added followed by the addition of a solution of 100 g. of m-bromotrifluoromethylbenzene in 300 ml. of ether over a two hour period. The resulting mixture is stirred for two hours at ambient temperature then cooled to 5° C. A solution of 70 g. of N-benzyl-3-piperidone in 300 ml. of ether is added at this temperature over one hour. After stirring for 15 minutes at 5° C. and one hour at 20°-25° C., the reaction mixture was poured onto 800 ml. of ice-water with stirring. The mixture is filtered, the organic layer extracted with 4×100 ml. of 1 N hydrochloric acid and once with brine. The aqueous phase is made alkaline by addition of triethylamine in the cold and the resulting mixture extracted with ethyl acetate. The combined extracts are washed with brine, dried (MgSO 4 ) and evaporated to dryness. The crude product is purified by silica gel chromatography, eluting with cyclohexane/chloroform/triethylamine (85:10:5 by volume) to obtain the desired product as an orange colored solid.
ii. N-Benzyl-3-acetoxy-3-(m-trifluoromethylphenyl)piperidine hydrochloride
A mixture of 37 g. of N-benzyl-3-hydroxy-3-(m-trifluoromethylphenyl)piperidine, 220 ml. of acetic anhydride and 0.3 ml. of concentrated sulfuric acid is heated to 110° C. for one hour. After cooling it is poured onto ice-water, the resulting mixture agitated for 15 minutes and made alkaline by addition of sodium hydroxide solution. The mixture is extracted with ethyl acetate, the extracts washed with brine, dried (MgSO 4 ) and evaporated to dryness to obtain 39 g. of the free base. This is dissolved in 600 ml. of ethyl acetate, cooled in ice, and 100 ml. of ethanol saturated with hydrogen chloride is added. The solvent is removed by evaporation in vacuo and the residue triturated with 200 ml. of ethyl acetate then 200 ml. of ethyl ether is added and the mixture allowed to stand overnight. The crystalline title compounds is collected by filtration, washed with ether and dried to obtain 36 g., M.P. 206°-207° C.
iii. The product obtained in Part ii is dissolved in 700 ml. of ethanol. Palladium-on-carbon catalyst (40 g). is added and the mixture hydrogenated at room temperature. When hydrogen uptake ceases the catalyst is removed by filtration and solvent evaporated in vacuo. The resulting solid is washed with ether and dried to obtain 21 g. of 3-(m-trifluoromethylphenyl)piperidine hydrochloride as colorless crystals, M.P. 200° C.
iv. Employing the appropriate cyclic aminoketone, selected from N-benzyl-3-pyrrolidone, N-benzyl-3-piperidine, N-benzyl-4-piperidone, N-benzyl-4-oxo-azacycloheptane and N-benzyl-4-oxo-azacyclooctane, and the appropriate R 7 Hal (where Hal is Cl, Br or I) in the above procedure the following compounds are obtained in similar manner.
______________________________________ ##STR150##a n R.sup.7______________________________________1 2 CH.sub.31 2 CH.sub.3 (CH.sub.2).sub.51 2 (CH.sub.3).sub.2 CHCH.sub.21 2 C.sub.6 H.sub.51 2 C.sub.6 H.sub.4 CH.sub.21 2 4-ClC.sub.6 H.sub.4 CH.sub.21 2 3-CH.sub.3 C.sub.6 H.sub.41 3 (CH.sub.3).sub.2 CH1 3 CH.sub.3 (CH.sub.2).sub.41 3 3-FC.sub.6 H.sub.41 3 4-CH.sub.3 OC.sub.6 H.sub.4 CH.sub.22 2 4-HOC.sub.6 H.sub.42 2 3-CH.sub.3 SO.sub.2 C.sub.6 H.sub.42 2 2-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.4 CH.sub.22 3 CH.sub.3 CH.sub.22 3 4-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.42 3 CH.sub.3 (CH.sub.2).sub.32 3 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.22 3 4-FC.sub.6 H.sub.43 3 CH.sub.33 3 C.sub.6 H.sub. 53 3 C.sub.6 H.sub.5 CH.sub.23 3 4-CH.sub.3 C.sub.6 H.sub.43 3 3-CH.sub.3 OC.sub.6 H.sub.4______________________________________
PREPARATION L
i. 3-Benzoylpiperidine hydrochloride
The method is that of U.S. Pat. No. 3,576,810. To 500 ml. of thionyl chloride was added 85.6 g. (0.5 mole) of 1-acetylnipecotic acid. The stirred mixture was heated at ca. 60° C. for two hours and then the solvent was evaporated at reduced pressure. The crude acid chloride was taken up in 200 ml. of dry benzene and the resulting solution added slowly to a mixture of 133 g. (1.0 mole) of aluminum chloride in 400 ml. of dry benzene. After the addition was complete the mixture was refluxed one hour and then poured onto cracked ice. The organic layer was separated and the aqueous layer was extracted with benzene. The combined extracts were dried over magnesium sulfate and the solvent was evaporated at reduced pressure. The residual oil which did not crystallize on cooling was distilled at reduced pressure and the fraction boiling at 160°-170° C./0.05 mm. collected. The crude product weighed 50 g. A mixture of 50 g. of the crude 1-acetyl- 3-benzoylpyrrolidine and 200 ml. of 6 N hydrochloric acid was refluxed 12 hours, cooled and extracted with benzene. The combined extracts were washed with water, dried over magnesium sulfate and the solvent evaporated at reduced pressure. The residual oil weighed 15.1 g. (16% yield). A portion (2.5 g.) of the free base was dissolved in 50 ml. of isopropanol and treated with ethereal hydrogen chloride. The white crystalline salt which formed weighed 2.4 g. and melted at 193°-195° C.
ii. Employing the appropriate N-acetylamino acid in place of N-acetylnipecotic acid and benzene or the appropriately substituted benzene in each case, the following compounds are obtained by the above procedure. When R 8 is OH the starting material is the corresponding acetate and the final product is obtained after hydrolysis, if desired.
______________________________________ ##STR151##a n R.sup.8 a n R.sup.8______________________________________1 2 H 2 2 4-CF.sub.31 2 4-Br 2 2 2-CH.sub.3 O1 2 4-OH 2 3 4-F1 3 H 2 3 3-CH.sub.3 SO.sub.21 3 2-Cl 3 3 4-OH1 3 4-Cl 3 3 4-F______________________________________
PREPARATION M
N-(1,4-Benzodioxan-2-carbonyl)piperazine
1,4-Benzodioxan-2-carboxylic acid, prepared by oxidation of 2-hydroxymethyl-1,4-benzodioxan with potassium permanganate in aqueous potassium hydroxide at 5°-15° C., was converted to the acid chloride by reaction with thionyl chloride in the standard manner.
A suspension of piperazine (11.88 g.) and sodium acetate (20.30 g.) in a mixture of water (70 ml.) and acetone (95 ml.) was stirred at 10°-15° C., then concentrated hydrochloric acid was added (about 35 ml.) until the pH of the solution reached 1.5. 1,4-Benzodioxan-2-carbonyl chloride (31.0 g.) and sodium hydroxide (5 N, about 45 ml.) were then added portionwise while maintaining the temperature at 10°-15° C., the sodium hydroxide maintaining the pH at 1.7-2.2. After the addition was complete, the pH was adjusted to 2.0 by the addition of sodium hydroxide, the suspension was stirred for a further 30 minutes. Water was then added until a homogeneous solution resulted, the acetone removed in vacuo, and the aqueous phase was basified to pH 8-9 with sodium hydroxide (5 N), re-extracted with chloroform (3×200 ml.) and the extracts washed with water, dried (MgSO 4 ) and evaporated in vacuo. The oily residue was dissolved in ethyl acetate, treated with ethereal hydrogen chloride, evaporated in vacuo and the solid residue triturated with ether, followed by recrystallization from methanol to give N-(1,4-benzodioxan-2-carbonyl)piperazine hydrochloride (4.85 g.), M.P. 265°-267° C.
PREPARATION N
N-Acetyl-4-allyloxypiperidine
A solution of N-acetyl-4-hydroxypiperidine (100 g.) in dimethylformamide (250 ml.) was added dropwise to sodium hydride (38 g., 50% mineral oil dispersion) under an atmosphere of nitrogen. The mixture was stirred for 2 hours then allyl bromide (93 g.) was added slowly whilst maintaining the reaction temperature at 25° C. by external cooling. The mixture was then stirred at room temperature overnight, diluted with isopropanol (20 ml.) and ether (500 ml.), filtered, and evaporated in vacuo. Distillation of the residue gave N-acetyl-4-allyloxypiperidine (108.8 g.), B.P. 128° C./2 mm., identified spectroscopically.
PREPARATION O
4-(2-Methoxy-n-propoxy)piperidine
A solution of N-acetyl-4-allyloxypiperidine (6.4 g.) in dry methanol (10 ml.) is added dropwise to a stirred suspension of mercuric acetate (11.5 g.) in methanol (50 ml.) at room temperature. After 20 minutes the mercuric acetate is dissolved and the mixture is stirred for a further 40 minutes, cooled in ice-water, and sodium hydroxide (20 ml., 5 N) is then added. A yellow precipitate formed during the addition. A solution of sodium borohydride (1.3 g.) in sodium hydroxide (20 ml., 5 N) is then added, the mixture stirred for 10 minutes, and acetic acid added to bring the pH to 6. The mixture is filtered from precipitated mercury, the ethanol evaporated in vacuo, and the resulting aqueous phase extracted with chloroform.
The organic extracts are dried (Na 2 SO 4 ), evaporated in vacuo, and the resulting crude residue taken up in methanol (50 ml.) and heated under reflux overnight with sodium hydroxide (20 ml., 5 N) and water (20 ml.). Most of the alcohol is then removed in vacuo, the aqueous layer extracted with ether, the extracts dried (Na 2 SO 4 ) and evaporated to leave a residue. The residue is treated with hydrochloric acid (20 ml., 2 N) and heated on a steam bath for 10 hours. The mixture is then washed with ether, the aqueous phase basified (Na 2 CO 3 ), extracted with ether and the organic extract dried (Na 2 SO 4 ) and evaporated to leave a resiude. Distillation of the residue at reduced pressure affords the title compound.
PREPARATION P
4-(2-Hydroxy-n-propoxy)piperidine
N-Acetyl-4-allyloxypiperidine (18 g.) in tetrahydrofuran (30 ml.) was added dropwise to a stirred yellow suspension of mercuric acetate (34 g.) in a mixture of water (120 ml.) and tetrahydrofuran (120 ml.). The suspension dissolved during the addition and the resulting clear solution was stirred at room temperature for 20 minutes, then sodium hydroxide (70 ml., 5 N) was added, accompanied by ice/water cooling. The intermediate thus obtained was then reduced by the addition of sodium borohydride (2 g.) in sodium hydroxide (40 ml., 5 N), the excess hydride being destroyed after 10 minutes with glacial acetic acid. The liquid phase was then decanted off, saturated with sodium chloride, the organic phase separated, and the remaining aqueous layer extracted four times with chloroform. The combined organic phases were dried (Na 2 SO 4 ), and evaporated in vacuo to leave a colorless oil (23 g.).
This oil was stirred with 5 N sodium hydroxide at room temperature for 16 hours, then at 100° C. for 2 hours. The solution was then extracted with chloroform (four times), the combined extracts dried (Na 2 SO 4 ), and evaporated in vacuo to leave a crude crystalline product (16.1 g.). This was taken up in methylene chloride, filtered, evaporated, and the residue triturated with petroleum ether (B.P. 40°/60° C.) to yield 4-(2-hydroxy-n-propoxy)piperidine (11.0 g.), M.P. 55°-57° C. The oxalate salt thereof was prepared by combining ethereal solutions of the two reactants and recrystallized from isopropanol, M.P. 104°-105° C.
PREPARATION Q
4-(3-Methoxypropoxy)piperidine
A solution of N-acetyl-4-hydroxypiperidine (30.5 g.) in dimethylformamide (200 ml.) is added dropwise to a stirred suspension of sodium hydride (11.26 g., 50% dispersion in mineral oil) in dimethylformamide (300 ml.) under an atmosphere of nitrogen. The reaction temperature is kept below 30° C. by external cooling and, after the addition is complete, stirring is continued for a further 11/4 hours. A solution of 1-bromo-3-methoxypropane (35.2 g.) in dimethylformamide (100 ml.) is then added dropwise with external cooling, and the resulting clear solution is stirred at room temperature overnight. The reaction mixture is then evaporated in vacuo, the residue partitioned between water and chloroform, the organic extracts dried (Na 2 SO 4 ) and evaporated to leave a crude residue. The above aqueous phase is saturated with sodium chloride, further extracted with chloroform, and the organic phase is dried (Na 2 SO 4 ), and evaporated to leave a further residue. This residue is combined with the original residue and heated on a steam bath overnight with hydrochloric acid (243 ml., 2 N). The reaction mixture is extracted with chloroform to remove the residual mineral oil, the aqueous phase concentrated, basified with sodium hydroxide (pH 12), then reextracted with chloroform. The organic extracts are washed with brine, dried (Na 2 SO 4 ) and evaporated to afford the desired product. | 2,4-Diaminoquinazolines of the formula ##STR1## wherein Y 1 is hydrogen or chloro, Y 2 is OR, Y 3 is hydrogen or OR such that when Y 1 is hydrogen, Y 3 is OR and when Y 1 is chloro, Y 3 is hydrogen or OR, and the pharmaceutically acceptable salts thereof; R represents an alkyl group having from one to three carbon atoms;
taken separately, R 1 and R 2 are each hydrogen, alkyl having from one to five carbon atoms, cycloalkyl having from three to eight carbon atoms, alkenyl or alkynyl each having from three to five carbon atoms or hydroxy substituted alkyl having from two to five carbon atoms, when taken together with the nitrogen atom to which they are attached R 1 and R 2 form a substituted or unsubstituted heterocyclic group optionally containing an atom of oxygen, sulfur or a second atom of nitrogen as a ring member; their use as antihypertensive agents, pharmaceutical compositions containing them and intermediates for their production. | 2 |
BACKGROUND OF THE INVENTION
This invention relates generally to installation of loudspeakers in vehicles; and more particularly, to installation and use of a relatively large speaker cabinet or container in a vehicle, so as not to interfere with luggage loading and transport.
There is need in vehicles for relatively large loudspeaker cabinets or containers, for desired acoustic effects. However, this presents a problem, particularly in small vehicles, such as those frequently used to carry luggage and other equipment. Such large-sized containers occupy needed storage space. There is also need for speaker boxes that can be shifted in a vehicle to alter the acoustics provided by the speakers.
SUMMARY OF THE INVENTION
It is a major object to provide an improved speaker container that is shiftable, while in installed position, to improve storage space in vehicles, such as a utility vehicle. Basically, the improved speaker container or box is adapted to fit at the rear of a utility vehicle seat, and comprises:
a) a box body that is horizontally elongated, has front and rear sides, opposite horizontally spaced ends, a top and a bottom,
b) means associated with the body to accommodate body swinging between rearward upright position, and forward stowed position, thereby to provide supportive storage spaces in both positions,
c) and speaker means carried by the body to direct sound within the vehicle in each of said body positions.
Another object of the invention includes provision of tweeter, mid range, or other speaker means carried by the body to direct sound forwardly in body upright position, and to direct sound downwardly in the body forward lowered position.
A further object is to locate the speaker means at the body forward side in body upright position.
Yet another object is to provide means attached to the body to accommodate body swinging, including hinge means attached to a lower portion of the body which projects forwardly and downwardly in body upright position. As will be seen, the hinge means or pivot is connected to a vehicle floor panel; and the speaker means is carried by the lower portion of the body, the body having L-shape, to project rearwardly above the vehicle floor panel in body upright position. Latch means is typically carried by a lateral extension of a rearwardly projecting upper extent of the body, to releasably connect to vehicle structure to retain the speaker body in upright position. Extended storage space is thereby provided and for luggage support.
Also, the body may be secured against theft in upright position, by means of one or more concealed locking pins accessible only in body folded position.
A further object includes provision of a vehicle seat directly forwardly of the body, the seat occupying a first position when the body is in the rearward upright position, and the seat occupying a second and forwardly collapsed position when the body is swung to forward lowered position in which the body extends into space at the seat first position. A first pivot structure is typically provided at a relatively rearward location, and there being a second pivot structure attached to the seat, forwardly of the first pivot structure.
A further object includes provision of a plastic molded speaker box designed to fit behind the seat of small sport utility vehicles. When the box is fastened in its upright position, it allows the user to have a secure storage area behind it. When the latch or bolt is removed from the mounting bracket and the box is folded forward, it allows the user to have an unobstructed load area.
These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which:
DRAWING DESCRIPTION
FIG. 1 is a side elevation showing a speaker box or container installed in a vehicle between a rear wall or tailgate, and the rear side of a seat;
FIG. 2 is a view like FIG. 1 showing the box collapsed forwardly, as the seat is likewise collapsed to provide maximum storage space;
FIG. 3 is a vertical elevation taken on lines 3--3 of FIG. 1;
FIG. 4 is a vertical section taken on lines 4--4 of FIG. 1;
FIG. 5 is an enlarged plan view taken on lines 5--5 of FIG. 1; and
FIG. 6 is an enlarged section taken on lines 6--6 of FIG. 5.
DETAILED DESCRIPTION
In the drawings, a sports utility vehicle 10 has a front panel 11 and a rear wall 12, such as a tailgate. A rear seat structure 13 is located in the vehicle forwardly of wall 12, and typically has pivoted connection at 14 to the floor panel. Structure 13 includes a seat cushion 15 and a back cushion 16 having a frame pivotally connected to the seat cushion frame, as via bracket 17. The latter is shown as connected at 17a to the frame of 15 and at 17b to the frame of 16. This allows the rear seat structure 13 to be forwardly collapsed, as seen in FIG. 2, that view showing the seat structure pivoted counterclockwise at 18 about the horizontal axis of 14. Also, the back cushion 16 is pivoted forwardly to collapse toward 15, as shown, with horizontal pivotal axes at 17a and 17a accommodating such collapse. Other means for allowing forward collapse of the rearward seat structure may be provided.
In accordance with the invention, a hollow speaker box or container 20 is installed, as shown in FIG. 1, between the rear side 16a of 16 and the front side 12a of gate 12. The front side of the box at 21 is angled upwardly and rearwardly to correspond to the rear side angularity of the seat back 16a. Also, the box projects rearwardly at 22 into proximity at 22a to the rear wall 12, providing a flat, upper surface or ledge 22c for supporting luggage in space 45 above 22. Thus, the box takes advantage of the available space, it being desired that a large speaker box be provided for desired acoustical effects. The box projects downwardly at 23 and is connected by a bracket 24 to a horizontal pivot 25. The latter is in turn connected at 26 to the floor panel, whereby the box may be swung between the positions shown in FIG. 1 and FIG. 2 about the horizontal axis of 25.
Note that in FIG. 2 the box projecting extent 22 extends upwardly and forwardly into proximity to the underside 15a of the seat cushion; and the box elongated extent 23 extends generally parallel to the floor panel 11 and in proximity thereto. Thus, projected extent 22 is near gate 12 in FIG. 1, and near the underside of seat cushion 15 in FIG. 2.
Accordingly, the unobstructed storage space 26 between wall 12 and the seat cushion 15 is maximized, as for storage of luggage and other equipment, as enabled by box 20 configuration. In this regard, the upper side 23a of the projected extent 23 of the box extends generally horizontally and parallel to floor panel 11, whereby it provides a flat luggage supporting area, facing upwardly.
The speaker box incorporates woofer speaker means 30 facing forwardly in FIG. 1, and carried by the box to direct sound forwardly in body rearward upright position, as seen in FIG. 1.
In FIG. 2, the woofer 30 faces downwardly toward the floor panel 11, whereby some muffling of the woofer sound is achieved in speaker body forward lowered position, as may be desired for varied acoustical effect.
Also, two tweeter speakers 35, as seen in FIG. 4, are carried by the body laterally of the larger woofer 30, and at laterally sidewardly angled extents 37 of the body, whereby tweeter sound may be directed forwardly in body upright position and toward laterally opposite sides of the seat rear 16a.
Likewise, in box lowered position, the tweeters 35 are spaced above the floor panel 11 and are laterally upwardly angled relative to the front panel, to direct sound laterally and upwardly. Thus, the tweeter sound is not completely muffled, nor is the woofer sound completely muffled in FIG. 2, since the side 20a of the box 20 elongated extent 23 is angled relative to the plane of the floor panel. The speaker box engages the floor panel at 38, forwardly of the tweeters and woofer, whereby the latter are not damaged, but are held raised relative to the floor panel.
Note again in FIG. 1 that the body has general L-shape to project rearwardly at 22. Latch means is carried by that rearward projecting body extent to releasably connect to vehicle structure, as best seen in FIG. 3, thereby to retain the speaker body in upright position. Note, for example, the large pins 40 in FIG. 3 extending between lateral projections 41 associated with the speaker body 20 and a vehicle structure 42 represented by the vehicle wheel wells or housings. Inward retraction of the pins 40 toward the interior of the box releases the box from structures 42 allowing pivoting. Structure 42 has top surfaces 42c providing lateral extensions of ledge 22c, for additional support of luggage, etc., indicated at 48.
FIGS. 5 and 6 show the bracket at 26 having a flat, lower portion 26a connected by a pin 26b to the vehicle floor panel 11.
Unusual advantages of the invention includes those described above, as respects its pivoting, latching, and woofer and tweeter locations in body upright and forward collapsed positions; and that also include ease of installation in and removal from a utility vehicle, as described.
The speaker body is typically made of plastic with or without glass fiber strengthening; and it is normally hollow for desired acoustic effects. Wire for carrying audio signals to the speakers is schematically shown at 50 and 51 in FIG. 4, as connected to a tape deck 52.
Pivots 25 may comprise concealed locking pins accessible only in body folded position, as in FIG. 2. In FIG. 1, pins 25 are concealed.
The box of the invention can be used with a woofer or woofers, with or without mid range and tweeter speakers of any number, and with or without an amplifier attached either inside the box body or surface mounted to the body. | A speaker box adapted to fit at the rear of a vehicle seat and comprising a box body that is horizontally elongated, has front and rear sides, opposite horizontally spaced ends, a top and a bottom; structure associated with the body to accommodate body swinging between rearward upright position, and forward stowed position, providing storage spaces in both positions; and speaker structure carried by the body to direct sound effectively within the vehicle in each of the body positions. | 1 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to pressure exchangers for transfer of energy from one liquid flow to another. More specifically, this invention relates to pressure exchangers for the transfer of energy from one liquid stream to another using a rotating split rotor exhibiting enhanced/proportional sealing and wear adjustment characteristics.
[0002] The present invention provides a device which can be appropriately described as an engine for exchanging pressure energy between relatively high and relatively low pressure fluid systems, which the term fluid being defined here as including gases, liquids and pumpable mixtures of liquids and solids. The engine for pressure energy exchange of the present invention is a highly efficient device with well over 90% of the energy of pressurization in a pressurized fluid system being transferred to a fluid system at a lower pressure. The device employed for achieving this highly efficient transfer has a long and trouble free operating life which is not interrupted by the plugging and fouling of valves, or the binding or freezing of sliding pistons or the like.
[0003] In processes where a liquid is made to flow under pressure, only a relatively small amount (about 20%) of the total energy input is consumed in pressurizing the liquid, the bulk of the energy being used instead to maintain the fluid in flow under pressure. For this reason, continuous flow operation requires much greater energy consumption than non-flow pressurization.
[0004] In some industrial processes, elevated pressures are required only in certain parts of the operation to achieve the desired results, following which the pressurized fluid is depressurized. In other processes, some fluids used in the process are available at high pressures and others at low pressures, and it is desirable to exchange pressure energy between these two fluids. As a result, in some applications, great improvement in economy can be realized if pressure exchange can be efficiently transferred between two.
[0005] By way of illustration, a specific process of this type is the exchange crystallization process for effecting desalination of sea water, or other saline aqueous solutions. In this process, a slurry of ice and an exchange liquid, such as a hydrocarbon, is placed under extreme pressure in order to reverse the order of freezing so that the ice crystals melt, and the exchange liquid is partially frozen. Following this step of the desalination process, the water from the melting of the ice is separated from the hydrocarbon, which is in the form of a slurry of solid hydrocarbon particles with the liquid hydrocarbon, and the separated phases are then depressurized to near atmospheric pressure. The economy with which the exchange crystallization desalination process can be practiced is directly dependent upon the efficiency with which the energy input to the process upon pressurization of the ice-exchange liquid system can be recovered after separation of the water-exchange liquid phases.
[0006] Another example where a pressure exchange engine finds application is in the production of potable water using the reverse osmosis membrane process. In this process, a feed saline solution is pumped into a membrane array at high pressure. The input saline solution is then divided by the membrane array into super saline solution (brine) at high pressure and potable water at low pressure. While the high pressure brine is no longer useful in this process as a fluid, the pressure energy that it contains has high value. A pressure exchange engine is employed to recover the pressure energy in the brine and transfer it to feed saline solution. After transfer of the pressure energy in the brine flow, the brine is expelled at low pressure to drain.
[0007] Accordingly, pressure exchangers of varying design are well known in the art. U.S. Pat. No. 3,431,747 to Hashemi et al. teaches a pressure exchanger for transfer of pressure energy from a liquid flow of one liquid system to a liquid flow of another liquid system. This pressure exchanger comprises a housing with an inlet and outlet duct for each liquid flow, and a cylindrical rotor arranged in the housing and adapted to rotate about its longitudinal axis. The cylindrical rotor is provided with a number of passages or bores extending parallel to the longitudinal axis and having an opening at each end.
[0008] A separation device may be inserted into each bore for separation of the liquid systems. The movement of the separation device is limited due to the use of a seat at each end of the passages. The seats cause a reduction in cross-area of the bores and are susceptible to wear and eventual failure.
[0009] Referring to FIG. 3 which shows a cross-section of the prior art exchanger, a major drawback of the prior art is the reduction in sealing surface-area between the inlet and outlet ports. The two ducts are separated by a very thin wall, thereby requiring extremely tight fitting components to ensure an acceptable level of sealing and the prevention of pressure loss between the high and low pressure ports. Leakage between these two ports results in reduced efficiency of the pressure exchanger, and as the tight tolerances of the mechanical components begin to wear, leakage between the ports will only increase and require costly maintenance as shown in FIG. 3 . Attempts have been made to incorporate springs and seals at the ends of the passageways to reduce leakage. Due however to the obvious drawbacks of this approach, the seals eventually wear out and or the springs degrade overtime, both of which require expensive downtime and repair. In addition, seals of this nature function properly only when they are aligned with the housing bores. During a single rotation, alignment of the rotor bore and the housing bore occurs only for a brief moment during the cycle. A seal with intermittent sealing capability is undesirable since leakage of high pressure fluid to the low pressure conduit represents a reduction in efficiency of the device.
[0010] There therefore is a need for a pressure exchanger which provides both smooth and uninterrupted fluid exchange as well as enhanced sealing capability thereby reducing the amount of leakage that occurs between the high and low pressure ports.
SUMMARY OF THE INVENTION
[0011] In accordance with a general aspect of the present invention, a pressure exchange apparatus for the transfer of a fluid is provided which consists of a housing having a low pressure inlet located at a first distal end of a housing and a low pressure outlet located at a second distal end of the housing. The low pressure outlet is in alignment with the low pressure inlet, and the housing also has a high pressure inlet located at the second distal end of and a high pressure outlet located at the first distal end of the housing. The high pressure inlet is in alignment with the high pressure outlet.
[0012] A left rotor is rotatably mounted inside the housing, with the left rotor having a first low pressure conduit and a first high pressure conduit running therethrough, both conduits are configured to align with the high pressure outlet and the low pressure inlet concurrently as the left rotor rotates. A right rotor, coaxially aligned with and offset from the left rotor is rotatably mounted inside the housing. The right rotor has a second low pressure conduit and a second high pressure conduit running therethrough, and both conduits are configured to align with the high pressure inlet and the low pressure outlet concurrently as the right rotor rotates.
[0013] A first tube is sealingly placed intermediate the left rotor and the right rotor is configured to communicate fluid between the first low pressure conduit and the second low pressure conduit. A second tube is sealingly placed intermediate the left rotor and the right rotor and is configured to communicate fluid between the first high pressure conduit and the second high pressure conduit. A spring disposed between the left rotor and right rotor is configured to bias the rotors apart thereby maintaining light contact with said housing. A motive force is provided to rotate the left and right rotor. A pressurized fluid is provided inside the housing to maintain sealing contact between the left and right rotor and the housing.
[0014] In accordance with another aspect of the invention, a system for the filtration of contaminated water to produce potable water is provided which has a low pressure pump configured to pump the contaminated water to a high pressure pump. A high pressure pump is provided to receive contaminated water from the low pressure pump and communicate the contaminated water to a filtration device at an elevated pressure. The filtration device is configured to produce potable water and waste water, with the waste water being expelled at an elevated pressure.
[0015] A pressure exchange pump is further provided to receive the waste water from the filtration device and contaminated water from the low pressure pump. The pressure exchange pump has a housing having a low pressure inlet located at a first distal end of the housing and a low pressure outlet located at a second distal end of the housing. The low pressure outlet is in alignment with the low pressure inlet, and the housing also has a high pressure inlet located at the second distal end of and a high pressure outlet located at the first distal end of the housing. The high pressure inlet is in alignment with the high pressure outlet. A left rotor is rotatably mounted inside the housing, with the left rotor having a first low pressure conduit and a first high pressure conduit running therethrough, both conduits are configured to align with the high pressure outlet and the low pressure inlet concurrently as the left rotor rotates. A right rotor, coaxially aligned with and offset from the left rotor is rotatably mounted inside the housing. The right rotor has a second low pressure conduit and a second high pressure conduit running therethrough, and both conduits are configured to align with the high pressure inlet and the low pressure outlet concurrently as the right rotor rotates.
[0016] A first tube is sealingly placed approximately intermediate the left rotor and the right rotor and is configured to communicate fluid between the first low pressure conduit and the second low pressure conduit. A second tube is sealingly placed intermediate the left rotor and the right rotor and is configured to communicate fluid between the first high pressure conduit and the second high pressure conduit. A spring disposed between the left rotor and right rotor is configured to bias the rotors apart thereby maintaining light contact with said housing. A motive force is provided to rotate the left and right rotor. A pressurized fluid is provided inside the housing to maintain sealing contact between the left and right rotor and the housing. This fluid acts on both the left and right sealing surfaces so as to exert a net force on said surfaces in proportion to the pressurized fluid pressure. The control of this pressure can be internal to the mechanism or external depending on system requirements. A controlled method requires an external valve and a feedback method such as a pressure gage.
[0017] In a further aspect of the invention, a pressure exchange apparatus for transferring the energy of pressurization between two fluids is provided, wherein one fluid is at a relatively higher pressure than the other. A first rotatably mounted rotor having a pair of spaced apart planar end faces, having at least one bore extending axially therethrough with each of the bores having an opening at each end thereof with the openings located in the planar end faces. A second rotatably mounted rotor being spaced apart from and coaxially aligned with the first rotor, the second rotor having a pair of spaced apart planar end faces, having at least one bore extending axially therethrough with each of the bores having an opening at each end thereof with the openings located in the planar end faces. A pair of closure plates rigidly affixed in close proximity to a respective end face of the first rotor and the second rotor. The closure plates slidingly and sealingly engaging the respective end face, and each of the closure plate having at least one fluid inlet passageway and at least one fluid discharge passageway, the passageways being positioned so that a fluid inlet passageway in one of the closure plates is aligned with the bore in the rotors at such time during the rotation of the rotors as a fluid discharge passageway in the other closure plates is aligned with the same bore. A pair of tubes slidably inserted axially between the first and second rotor is held in fluid communication with the bores such that fluid flows from a respective bore of the first rotor to a respective bore of the second rotor. A spring is inserted between the first and second rotor which is configured to bias the first rotor apart from the second rotor. A pressurized fluid acting is provided which acts upon a face of the first rotor and the second rotor to increase the sealing contact between the closure plates and the first and second rotors. The bore openings and passageways being positioned in their respective surfaces so that during rotation of the rotors, the openings at the end of each bore are, in alternating sequence, brought into concurrent alignment with an inlet passageway at one end of the respective bore and a discharge passageway at the other end of the respective bore, and then, at a different time, into concurrent alignment with a discharge passageway at one end of the respective bore and an inlet passageway opening at the other end of the respective bore. A motive force for cyclically rotating the rotors relative to the closure plate so that each of the bore openings periodically moves through the same path to repeatedly effect the alternating sequence of alignment of the bores with the passageways.
[0018] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a cross-sectional side view of the pressure exchange device;
[0020] FIG. 2 is a simplified block diagram of a filtration system utilizing the pressure exchange device in accordance with the present invention;
[0021] FIG. 3 is a cross-sectional view of the prior art.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0023] Referring first to FIG. 2 , which depicts a process flow diagram for a salt water filtration system 200 that uses a reverse osmosis process for the production of potable water which comprises a pressure exchange device 10 in accordance with the present invention.
[0024] A salt water reservoir 201 provides a supply of salt water which is pumped to a high pressure pump 204 by reservoir pump 202 . Typically the reservoir pump 202 supplies salt water to both the high pressure pump 202 and the pressure exchange device 10 at approximately 30 psi pressure at approximately equal flow rates. The high pressure pump 204 boosts the pressure to approximately 1000 psi and supplies the salt water to a filter element 208 . In this particular application, and not by way of limitation, the filter element 208 comprises a reverse osmosis type filter device which removes the impurities from the water and provides a fresh water supply 210 . A pressure drop occurs in the filter element 208 such that a supply of waste water 209 exits the filter element 208 at approximately 980 psi. Rather than dump this waste water 209 at this elevated pressure, the waste water 209 is supplied to a high pressure inlet 104 of the pressure exchange device 10 . This high pressure waste water is thus used to pressurize additional salt water for use in the filtration process. Reuse of this high pressure waste water 209 thus provides for a highly efficient filtration system 200 .
[0025] As mentioned previously, the reservoir pump 202 supplies salt water to a low pressure inlet 100 of the pressure exchange device 10 . The pressure exchange device 10 , as to be discussed in more detail below, is configured to raise the pressure of the salt water supplied to it by the reservoir pump 202 to a pressure equal to the pressure of the waste water 209 supplied to the high pressure inlet 104 .
[0026] A high pressure outlet 106 located on the pressure exchange device 10 is in fluid communication with a boost pump 214 . The waste water 209 from the high pressure outlet 106 is supplied to the boost pump 214 for example at approximately 960 psi and the boost pump 214 raises the pressure to 1000 psi and supplies the waste water to the filter element 208 for further filtration. Thus, a closed loop system is provided that maximizes the use of the waste water and reuses the high pressure waste water to increase system efficiency.
[0027] Referring to FIG. 1 , the operation of the pressure exchange device 10 will now be discussed in more detail. The pressure exchange device 10 is comprised of a sealed housing 16 having a first and second end plate 12 and 14 respectively affixed thereon. Provided in the first end plate 12 is a low pressure outlet 102 and a high pressure inlet 104 . Provided in the second end plate 14 is a high pressure outlet 106 and a low pressure inlet 100 .
[0028] Referring back to FIG. 2 , the low pressure outlet 102 is in fluid communication with a waste line 218 which is in fluid communication with a drain 220 . The low pressure inlet 100 is in fluid communication with the reservoir pump 202 and the high pressure outlet 106 is in fluid communication with the boost pump 214 . The high pressure inlet is in fluid communication with the filter element 208 and therefore receives the waste water 209 which is already at an elevated pressure.
[0029] Referring to FIG. 1 , a left rotor 18 a and a right rotor 18 b is rotatably mounted inside the housing 16 . Each rotor has at a minimum two opposing conduits. For ease of illustration in this sectional drawing these shall be referred to as a top conduit 32 and a bottom conduit 30 . These conduits are held in coaxial alignment with each other. A top tube 20 a and a bottom tube 20 b is sealingly inserted in a respective conduit between the left and right rotor 18 b and 18 a to bridge the gap between the rotors and thereby provide for a continuous passageway from the right rotor 18 a through the left rotor 18 b . A seal 36 is provided at each end of the top and bottom tubes 20 a and 20 b to reduce fluid leakage. With this configuration, when the rotor is in proper alignment with the ports on the end plates 12 and 14 , fluid may flow through the pressure exchange device 10 .
[0030] A spring element 28 is disposed in a step 26 which is formed in the left and right rotor 18 a and 18 b . The spring element 28 is configured to act against the top and bottom tubes 20 a and 20 b and thereby provide a preload force to separate the left and right rotors 18 b and 18 a to minimize the gap 24 between a sealing surface 46 and the rotors. It should be noted that the gap 24 as shown in FIG. 1 is exaggerated for illustration purposes. Thanks in part to the spring element 28 , the gap is actually very small, thereby reducing leakage during the initial start up phase. The sealing surface 46 is a hard coated surface provided on the inside wall of each end plate 12 and 14 to reduce leakage and wear that may occur from the rotors as they spin. The spring elements 28 therefore provide a preload between the sealing surfaces primarily to reduce leakage at the initial start up of the pressure exchange device 10 .
[0031] It should be understood that the location and configuration of the spring elements 28 may easily be modified as to location and type. For example, a single spring may be inserted between the left and right rotors 18 a and 18 b to provide the necessary sealing preload. All such modifications are fully contemplated by the present invention.
[0032] A shaft 22 is provided which runs coaxially through both the left and right rotor 18 a and 18 b . The shaft 22 is configured to provide the force to spin the rotors, but also allows for the left and right rotor to move along the longitudinal axis of the shaft 22 to maintain a proper sealing interface. This configuration may easily be accomplished by providing a spline or a keyway on the shaft 22 that allows the rotors to slide. The shaft 22 exits through a hole 23 in the first end plate 12 and is connected to a motive force such as a motor (not shown). A bearing 25 is provided in the first and second end plates 12 and 14 to support the shaft 22 and increase the overall system efficiency. An optional seal 27 reduces leakage to the environment between the housing end plate 12 and the shaft 22 .
[0033] An optional first separator 38 and second separator 40 may be disposed in the respective top and bottom conduits 30 and 32 . The separators 38 and 40 may be a sphere which is configured to translate back and forth in the respective conduit to aid in the pressure exchange process. The separators 38 and 40 may also be pistons with sealing elements disposed thereon.
[0034] A pressurized fluid 33 is provided internal to the housing 16 which acts to further separate the left and right rotor 18 b and 18 a and increase the sealing force acting on the sealing surface 46 and a respective face of the left and right rotors. The net sealing force is proportional to the difference in the pressurized fluid 33 acting to further separate left and right rotor 18 b and 18 a and the average force trying to close the left and right rotor 18 b and 18 a . Since the entire face of the rotor is subject to the pressurize fluid 33 while the sealing face 24 is subject to pressures that average lower than this pressure, there is a net force of separation of the rotors. This force is proportional to the difference in pressure between the pressurized fluid 33 pressure and the average face pressure 24 . The pressurized fluid 33 may be supplied from the working fluid such as the salt water which is to be filtered, or it may be supplied by a unique fluid source such as a pressurized fluid reservoir.
[0035] An orifice 34 is provided between the rotor and the inside of the housing 16 such that pressurized fluid is allowed to enter from the bottom (high pressure) conduit 30 and provide a supply of fluid to help maintain and regulate the pressure of the pressurized fluid 33 . It may also be advantageous to provide a bleed passage 42 which is in fluid communication with the pressurized fluid 33 and the low pressure inlet 100 to further regulate the pressure of the pressurized fluid 33 . A pressure gage 44 may be located on the housing 16 which is configured to measure and indicate the pressure of the pressurized fluid 33 . It would therefore be possible, through the use of dynamically controlled valves and pressure transducers, to provide a regulation system that produces a pressurized fluid that exhibits the optimum sealing force thus maintaining the pressure exchanger at peak efficiency.
[0036] Referring to FIGS. 1 and 2 , and as previously described, the pressure exchange device 10 operates to transfer the high pressure contained in the waste water 209 (approx. 980 psi) to the low pressure (approx. 30 psi) salt water supplied to the low pressure inlet 100 by the reservoir pump 202 . This is accomplished by spinning the left and right rotors 18 a and 18 b in unison such that the top conduit 32 and the bottom conduit 30 intermittently align with a respective inlet and outlet port of the pressure exchange device 10 . A plurality of bores through the rotor is desirable in order to even out the flow through the pressure exchanger and increase throughput.
[0037] For example, with the rotors 18 a and 18 b in the position shown in FIG. 1 , high pressure waste water is allowed to flow into the bottom conduit 30 through the high pressure inlet 104 . This high pressure flow forces separator 34 to push fluid that is already contained in the bottom conduit 30 (from the previous cycle) out the high pressure outlet 106 at the elevated pressure. Thus the low pressure fluid contained in the bottom conduit 30 has now been elevated to the high pressure. At the same time, the top conduit 32 is in alignment with the low pressure inlet 100 and receives low pressure salt water from the reservoir pump 202 . Since the low pressure outlet, as shown in FIG. 2 is attached to a drain (ie atmosphere), the flow of the low pressure fluid forces the separator 34 to the right and forces the fluid out of the bottom conduit 30 through the low pressure outlet 102 to a drain 220 . It should be noted that the low pressure fluid that just flowed into the bottom conduit 32 , will be the fluid that is pressurized to the higher pressure when the rotor spins 180 degrees and aligns with the high pressure inlet 104 , thereby repeating the pressure transfer all over again. Obviously, a plurality of conduits, of varying cross-sectional shapes and sizes, can be formed in the rotors 18 a and 18 b to increase the flow rate and even out the flow of fluid through the pressure exchange device 10 .
[0038] As the rotor assembly spins, the pressurized fluid 33 in the housing 16 acts against the rotor assembly to maintain a sealing pressure between the faces of the rotor assembly and the sealing surfaces 46 . As the two sealing surfaces wear over time, the pressurized fluid 33 maintains the correct sealing pressure such that over time, the efficiency of the pressure exchanger 10 is not substantially degraded and repairs are not required for long periods of time.
[0039] It should be understood, of course, that the foregoing relates to preferred embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. For example, the fluid pressures discussed herein were used as for illustration purposes only and should not be used to limit the appended claims. | A pressure exchange device is provided that utilizes a rotor assembly inside a housing to transfer the pressure of a fluid from one high pressure fluid to another low pressure fluid. The housing may comprise a pressurized fluid contained therein to provide a sealing force to reduce fluid leakage between the spinning rotors and the housing. The sealing force and wear characteristics may be controlled to reduce leakage and wear of the pressure exchange device. The rotor assembly may be driven in either direction and the high pressure ports may be switched with the low pressure ports if desired. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to boat trailer steps and in particular to boat trailer steps which are demountably attached.
2. Description of the Prior Art
The dangers of accidental drownings and injuries resulting from loading and unloading boats from trailers has long been recognized. Many boats are loaded and unloaded by sliding the boat on rollers. The winch cannot be disconnected until the boat is in the water when unloading, and when loading the winch line must be carried to the boat. The boat trailer frame members are extremely dangerous to walk on when wet, and many times the water temperature does not permit wading. To overcome these problems, trailer fenders have been used as steps and more recently permanent steps have been used. Permanent steps, by their very nature, are unsatisfactory because of individual preferences in footing, types and sizes of boats used with the trailers, and cost of construction. To satisfy individual preferences for footing in loading and unloading boats, permanent steps would have to be mounted around the complete periphery of the boat trailer, making for a bulky trailer, undesirable in appearance, costly in construction, and depending on size and shape of the boat, such a trailer might very well be unuseable.
BRIEF SUMMARY OF THE INVENTION
The present invention comprises a readily demountable boat trailer step including a foot plate with slots, bolts, clamp bars, and clamping means which provide a securedly affixed step attachable to a variety of boat trailer frame members.
It is therefore an object of the present invention to provide a boat trailer step which is demountably attached to boat trailer frame members at varying locations.
It is a further object of the present invention to provide a boat trailer step which may be attached to a boat trailer frame in series to provide individual footing preferences.
It is a still further object of the present invention to provide a boat trailer step which is demountably attached to varying sizes and shapes of boat trailer frame members.
Another object of the present invention is to provide a demountable boat trailer step having a foot plate made of expanded metal for sure footing.
Additional objects and advantages will become apparent and a more thorough and comprehensive understanding may be had from the following description taken in conjunction with the accompanying drawings forming a part of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a typical embodiment of the demountable step of the present invention shown attached to a boat trailer frame member.
FIG. 2 is an elevated perspective view of the present invention showing details of attachment.
FIG. 3 is a plan view of the step.
FIG. 4 is a bottom view of the step showing clamp bars.
FIG. 5 is an end view showing attachment to a rectangular frame member.
FIG. 6 is an end view showing the adapter device of the present invention mounted on a cylindrical frame member.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a typical embodiment of a demountable step assembly 10, made according to the present invention, is disclosed. Step assembly 10 includes rectangular foot plate 14, bolts 15, clamp bars 16 and wing nuts 17. Step assembly 10 is shown attached at several locations on boat trailer frame member 20 of trailer 22 for easy access to boat 24.
Referring now to FIG. 2, it will be seen that step assembly 10 may be attached at various locations along boat trailer frame member 20. It will also be seen that foot plate 14 may be moved to a number of positions horizonally transverse to frame member 20. This is accomplished by loosening wing nuts 17 on bolts 15 and simply sliding foot plate 14 to a new desired position. Slots 18 permit lateral movement of plate 14 in relation to bolts 15 located on each side of frame member 20. Tightening wing nuts 17 secures the step in a fixed relationship with the frame member by applying a downward clamping action on the top surface of the foot plate contacting the bottom surface of the head portion 19 of bolts 15, and an upward clamping action on the bottom surface of clamp bars 16 contacting the frame member.
Now, referring to FIGS. 3 and 4, foot plate 14 may be seen to advantage. Plate 14 is formed from a non-corrosive metal such as aluminum, or a metal covered with a corrosion resistant metal such as galvanized iron. The plate may also contain a skid resistant covering or paint. In the preferred embodiment, the plate is formed of expanded metal which has been galvanized. The expanded metal is the type conventionally used in the plastering art. In using expanded metal it is necessary that the portion of the plate surrounding the slots be smooth and flat to accomodate the head portions of bolts 15. The expanded metal portion may be attached to the smooth portion by welding or otherwise. Plate 14 has planar opposing sides providing for level footing and for maximum contact with frame member 20. The plate may be of any suitable size and thickness; a step 12 × 18 × 1 inches being contemplated. It is to be noted that the use of expanded metal in the foot plate prevents an accumulation of water on the plate and also gives good foot traction.
Bolts 15 are conventional round head, square shouldered, corrosion resistant bolts of a length sufficient to extend an inch or two beyond the depth of frame member 20. In most applications, four of the bolts are used to secure the foot plate to the boat trailer frame. Two bolts are placed through each of the slots 18 so that their square shoulders make loose contact with the interior lateral surfaces of opposing sides of each slot and so that the flat underside of the head portions 19 of the bolts abut flush with the upper surface of the plate 14. Each of the bolts in each slot is caused to straddle one side of the frame member 20 and each of the bolts in the other slot are caused to straddle the other side of the frame member. The bolts are then extended through holes 22 of clamp bars 16 and secured with wing nuts 17 as hereinafter more fully explained.
Clamp bars 16 are made of a corrosion resistant material such as galvanized iron. The bars contain a series of equally spaced holes 22 parallel to the sides of the bar, each of the holes being of slightly larger diameter than bolts 15. It is contemplated that the bars 16 will have crimped areas, not shown, every 2 or 3 inches which run across the width of the bar so that the bar may be broken at a desired length, thereby preventing bothersome overhangs.
Wing nuts 17 screw onto the threads of bolts 15 and contact the bottom surface of clamp bars 16, securely holding the step assembly to frame member 20. Although wing nuts are used in the preferred embodiment, it is understood that conventional nuts and other clamping means may be similarly employed.
Step assembly 10 is usually mounted on standard rectangular frames 20, as shown in FIG. 5. Sometimes, however, the boat trailer will have a cylindrical frame 20' as shown in FIG. 6. To adapt the step assembly to a cylindrical frame, a pair of frame adapters 30 and 30' are used. Frame adapters 30 and 30' are identical in construction and differ only as to the mounting as may be seen in FIG. 6. The frame adapters include a contact plate, designated 33 and 33' in the figure, and a semicircular support member, designated 35 and 35' attached at the midpoint by welding to the contact plate. The width of the contact plates are slightly greater than the diameter of the frame member 20'. The interior contact surface of the semicircular support members have a diameter equal to or greater than the outer diameter of frame member 20', it being desirable to maximize contact area between the interior surfaces of the semicircular support members and the exterior surface of the frame members. The frame adapters may be of any suitable length and are made of plastic or corrosion resistant metal.
It will be seen that the frame adapters are fitted conveniently around the boat trailer frame member 20'. The top surface of contact plate 33 of adapter 30 supports plate 14 on plate 14's under surface. The contact plate 33' of adapter 30' rests on the top surface of clamp bars 16. As wing nuts 17 are tightened, an upward clamping pressure is exerted on the clamp bars 16 and the adapter 30', forcing the interior surface of semicircular support member 30' in a tight and fixed relationship with the exterior surface of the cylindrical frame 20'. Similarly a tightening of wing nuts 17 exerts a downward clamping pressure on the plate 14 in contact with the head portion of bolts 15. Plate 14 thereby exerts a downward pressure on frame adapter 30 in contact with the top surface of cylindrical frame member 20'. In this manner a safe and reliable securing of the step assembly to the boat trailer frame may be made in a short time.
Having thus described in detail a preferred embodiment of the present invention, it is to be appreciated and will be apparent to those skilled in the art that many physical changes could be made in the apparatus without altering the inventive concepts and principles embodied therein. The present embodiment is to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore to be embraced therein. | A demountable boat trailer step including a foot plate having a pair of parallel slots adjacent each end and running substantially the full width of the plate, a plurality of bolts, a pair of clamp bars, and a plurality of nuts. The foot plate rests on the top surface of a boat trailer frame member and is demountably attached by means of bolts extending through the slots and engaging clamp bars contacting the undersurface of the frame member. Slots in the foot plate permit mounting on various sizes of frame members. Adapters are provided for attachment of the step to cylindrical frame members. | 1 |
This application is a continuation application of application Ser. No. 13/029,757 filed at United States Patent and Trademark Office on Feb. 17, 2011 by the present inventors, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to carrying out the movement of slide on the body in pistols having light alloy body structure, via a bearing component; which is placed in slide bearing, which has a more durable structure than the body, and made from steel material.
2. Background
Today, component of the pistols for bearing the barrel, known as slide, is made from steel, while its body component is made from aluminum alloy or made all-steel.
The pistols having aluminum alloy bodies are often preferred because they are inexpensive and light. However, the aluminum alloy bodies have certain disadvantages. For example, it is known that the aluminum body that comes into contact with steel slide abrades in time due to this contact and after some time it breaks. In addition to this, it has been observed that the aluminum, which has a quite low rupture-strain, cannot bear the load that arise during blast and that aluminum body crush during the firing of the pistol. For this reason, the aluminum alloy pistols are easy to use, yet their working lives are relatively limited.
In the state of the art, many alternative techniques have been tried in production of the body. For example, pistols having steel bodies have been produced; these are known to be heavier and much more robust compared to the aluminum. Here the aim is to eliminate deformations that arise as a result of the body's contact with the slide, and to lengthen the working life of the pistol by increasing its durability. Although the pistols with steel bodies that are much more resistant to the load that arise during blast of the pistol, result in lengthening of working life of the pistol, due to steel alloy's being relatively much heavier, they are not convenient for constant carriage and their use is difficult; therefore, these properties prevented such pistols from being preferred.
Also, although there has been attempts, as an addition to existent techniques, at production of pistols having both the body and slide made from aluminum; since the aluminum slide cannot bear the high load and heat that it is subjected to during the blast, it is not possible to produce the slide component of the pistol from aluminum.
Another material used in light alloy pistol bodies is titanium, which is known to be more durable than aluminum. However, titanium's being quite expensive precludes its advantage of durability. For this reason, pistols with titanium bodies are also not preferred often.
Pistols work through simple recoil force. When the bullet inside the barrel is fired, as the bullet is propelled forward within the barrel with the impact of the bullet's blast pressure, it pushes the slide backwards due to reverse force. The slide that is pushed backwards with backlash force begins to set the recovered recoil spring. With the effect of the set recoil spring, the slide, which comes to the distance calculated in design, rapidly returns to the position that it must rest. Pressure force that arise with the blast during the firing of the pistol, first impacts the slide that locks the barrel, then, with slide-barrel movement it impacts the body, and with the movement of the slide that is subjected to force and began to move, it impacts other components within the pistol. As it is understood, the more pressure impacts the body of the pistol, the bigger pressure impacts other components that make up the pistol and are inside the pistol. From time to time, this pressure force that acts on the said components that are inside the pistol may result in break down or breakage of these components. For this reason, in order to ensure a long working life for the pistol or other components that make up the pistol, the pressure force acting on these components must be kept at minimum.
This high pressure that arises during the blast has negative effects on the body of the pistol; these negative effects have been subject of certain patents and useful models. For example, in U.S. Pat. No. 1,563,675, elastic disks that are placed inside the body are used in order to counter the pressure and high energy that arise in pistols during firing. As for U.S. Pat. No. 1,754,689, once more, for countering the pressure that effect the body and absorbing a part of the energy that arise; between the slide and body, nylon material “delrin” is used, while in invention U.S. Pat. No. 3,756,121, nylon material “zytel” is used. As for U.S. Pat. No. 4,344,352, it mentions a recoil spring system that can counter the recoil force.
As it is understood, generally, the high energy and pressure that particularly act on the body and slide in pistols have been subject of many inventions and these inventions always take the direction of subsequent addition, to the pistol, of apparatuses having property of elasticity but have short working life; therefore, no long-lasting solutions have been found for the above mentioned deformation problem.
SUMMARY OF THE INVENTION
The bearing component ( 5 ) that is the subject of the invention is intended for prevention of deformations of the aluminum alloy body ( 1 ) caused by high temperature that arise during the firing of the pistol and weight that arise from pressure, and lengthening of the working life of the pistol.
BRIEF DESCRIPTION OF DRAWINGS
Explanations of the figures pertaining to the invention are as follows:
FIG. 1 : General view of the light alloy pistol having the bearing component
FIG. 2 : Movement of the recoil spring guide during the moment of firing
FIG. 3 : Detail view of the light alloy pistol having the bearing component
REFERENCES
1 . Pistol body
2 . Slide
3 . Barrel
4 . Recoil spring guide
5 . Bearing component
6 . Slide stop
7 . Retaining pawl
8 . Assembly hole
9 . Recoil spring
10 . Slide bearing
DESCRIPTION OF THE INVENTION
In the system that is subject of the invention, an area of the slide bearing ( 10 ) has the following characteristics: it engages with inner surface of the body ( 1 ) when placed inside the body ( 1 ), it has an outer surface geometry with a specially designed indented structure, it is independent of the body ( 1 ) of the pistol, it can be assembled and disassembled when necessary, and it is an all-steel production. The said slide bearing component ( 5 ) is inserted into the body ( 1 ) of the pistol that has aluminum alloy structure, to the slide bearing ( 10 ), and serves the function of bearing the slide ( 2 ).
Outer surface geometrical shape of the bearing component ( 5 ) that is the subject of the invention, has a specially designed indented structure that engage with the inner surface of the body ( 1 ), and at side surface edges there is one retaining pawl ( 7 ) for each surface, which enable the component ( 5 ) to fasten onto the body ( 1 ) also from the outside. When the slide bearding component ( 5 ) is inserted into the body ( 1 ) of the pistol, on each side there are assembly holes ( 8 ) into which the slide stop ( 6 ) will enter. Thus, the slide stop ( 6 ) that resides inside the body ( 1 ) also helps fastening of the bearing component ( 5 ) to the body ( 1 ).
In the pistols with light alloy body ( 1 ) having the bearing component ( 5 ) that is the subject of the invention; when the bullet inside the barrel ( 3 ) is fired, as the bullet is propelled forward within the barrel ( 3 ) with the impact of the bullet's blast pressure, due to reverse force it pushes the slide ( 2 ) backwards. The slide ( 2 ) that is pushed backwards with backlash force begins to set the recovered recoil spring ( 9 ). With the effect of the set recoil spring ( 9 ), the slide ( 2 ), which comes to the distance calculated in design, rapidly returns to the position that it must rest. The pressure force that arise with the blast during the firing of the pistol, first impacts the bearing component ( 5 ) that locks the barrel ( 3 ), and then it impacts other components within the pistol.
Owing to the steel bearing component ( 5 ) that is inserted into the slide bearing ( 10 ), in the area where the blast takes place, the slide mechanism ( 2 ) contacts not with the aluminum body ( 1 ), but with the steel bearing component ( 5 ). Thus, the aluminum body ( 1 ), which is indurable and has short working life, is not affected by the contact and the contact does not result in any deformations in the aluminum alloy body ( 1 ) of the pistol.
In present situation of the art, contrary to the above mentioned patent examples, the bearing component ( 5 ) has the following characteristics: it is not an elastic structure placed in the body ( 1 ) but it engages with inner surface of the body ( 1 ); it has an outer surface geometry with a specially designed indented structure; it is an all-steel production; it moves in combination with the pistol components such as the slide stop ( 6 ) and recoil spring guide ( 4 ) inside the pistol, and it can be assembled and disassembled when necessary.
The bearing component ( 5 ) placed inside the body ( 1 ) has many functions. As it is clear from its name, the bearing component ( 5 ) bears the slide ( 2 ) and by providing steel-steel contact in the area where the blasting takes place, prevents the contact of the aluminum alloy body ( 1 ) with the steel slide mechanism ( 2 ).
After the firing of the pistol, the barrel ( 3 ) makes a 3 degree angle with movement of the slide ( 2 ). Greatest function of the bearing component ( 5 ) is fastening the recoil spring guide ( 4 ) by containing the slide stop ( 6 ), bearing the barrel ( 3 ) with the help of the recoil spring guide ( 4 ), and fastening the barrel ( 3 ) that makes a 3 degree angle due to return of the slide ( 2 ) in this position, again with the help of the recoil spring guide ( 4 ). This situation, which recoil with backlash force and has the barrel ( 3 ) make a 3 degree angle, is of high-impact and all of this impact is countered by the bearing component ( 5 ).
Another function of the bearing component ( 5 ) that is the subject of the invention is its ability to bear and fasten the recoil spring guide ( 4 ), which is a movable component like the barrel ( 3 ), by containing the slide stop ( 6 ). Thus, as shown in FIG. 2 , the said bearing component ( 5 ) determines the numeric value of the recoil spring guide ( 4 ), that is, it determines where the recoil spring guide ( 4 ) will stop during the firing and prevents the slide ( 2 ) from hitting the body ( 1 ). Thus, the loads that arise during the firing are countered not by the aluminum alloy body ( 1 ) but by the steel bearing component ( 5 ) and such negative effects as crushing and abrasion, which are caused by the loads that arise during the firing, are minimized.
Owing to the bearing component ( 5 ) that is the subject of the invention, a big part of the pressure force that arise during the blast with firing of the pistol is countered by the bearing component ( 5 ). By this means, loads coming to other components within the system are minimized and breakages and break downs that are often observed in these components are prevented to a great extent.
With the bearing component ( 5 ) that is the subject of the invention, working lives of the pistol and the components that make up the pistol are lengthened and a higher rate of fire is achieved.
Principles, preferred configuration, and manner of work of the present invention are described through the above explanations. However, this component ( 5 ) that is the subject of the invention, which is intended to be protected, must not be interpreted as limited only to the steel bearing component ( 5 ); all materials that are more durable than the light alloy body ( 1 ) of the pistol must be evaluated within the scope of the invention. | This invention relates to countering of the weight caused by high temperature and pressure that arise during the firing of the pistol by this component, instead of the aluminum alloy body; by inserting, into the pistol with light alloy body structure, a bearing component that is all-steel, independent of the body of the pistol, and that can be assembled and disassembled when necessary; elimination of deformations of the aluminum alloy body caused by the high temperature and high pressure; and lengthening the working life of the pistol by increasing the rate of fire. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
This application claims priority under 35 U.S.C. §119 (e) to U.S. Provisional Application Ser. No. 60/309,967, filed Aug. 3, 2001. This application is also related to co-pending U.S. patent application Ser. No. 10/211,809 and U.S. patent application Ser. No. 10/211,790 filed on even date herewith, each of which is incorporated by reference.
FIELD OF THE INVENTION
The present invention is related to a fastener for stucco sheathings, and more particularly, to a specially configured nail for use in construction of wood frame structures to which stucco is attached to the exterior thereof to improve the resistance of the stucco to shearing forces caused by seismic and hurricane lateral loading.
BACKGROUND
As observed, reported and learned from nine California earthquakes since 1951, existing portland cement-based exterior plaster (stucco) of wooden-framed structures has had little success in surviving intense lateral loads caused by earthquake, as well as hurricane forces. For example, the shaking intensity during the 1994 Northridge Earthquake, which in some locations reached magnitudes of 8 and 9 Modified Mercalli Intensity (MMI), was enough to detach stucco sheathings from the wooden frame of many one and two story single family residences and apartment buildings. Such detachment of the stucco sheathings from the wood framing resulted in heavy interior damage, uninhabitable structures and required the removal and replacement of the stucco sheathings.
A primary reason for the detachment of the stucco from the wood framing was the Uniform Building Code's approval of staples, since 1957, for attaching a reinforcing wire mesh to the wood framing prior to applying the stucco over the wire mesh coupled with the requirement of the Uniform Building Code in 1967 that a 26 gauge corrosion resisting continuous drip screed be installed against the mud sill plate, which is disposed along the lower portion of the wood framing. The mud sill plate has a minimum of a one inch overlap below the wood sill plate. The continuous drip screed is typically attached to the mud sill by the use of nails so that the stucco ends evenly just below the mud sill. Waterproof building paper and wire mesh or metal lath are then installed over the drip screed.
The wire mesh or metal lath is normally attached to the metal drip screed by use of the Uniform Building Code's specified staples, which are typically applied by use of a staple gun. Many times, the staple legs become bent and do not penetrate the metal drip screed. Staples used to fasten the wire mesh at the drip screed are often rusted out within a few years due to moisture rusting and weakening the thin staple legs. Stucco having poor lateral attachment to the mud sill due to unattached or rusted staples, typically fails at the wood sill plate during intense lateral displacement of the wood framing generated by such forces as earthquakes and/or hurricanes. Failure of the stucco sheathing generally results in heavy structural damage, often leaving the structure uninhabitable and needing complete replacement of the exterior stucco sheathing.
Therefore there is a need for a device and method of improving the strength of stucco sheathing against intense lateral forces, which is inexpensive and easily installed during new construction and prior to the application of portland cement plaster (stucco) to provide anchorage of stucco sheathings to the wood sill plates at the base of the wall and to other portions of the wood framing.
SUMMARY OF THE INVENTION
An exemplary embodiment of the present invention includes a fastener comprising a body having a predetermined axial length, wherein the body comprises a nail head at one axial end of the body, a textured portion at an opposite axial end of the body and a shank portion extending between the nail head and the textured portion, and wherein the shank portion has an axial length in excess of at least one-third of the axial length of the fastener body. The body further comprises a raised ring integrally formed in the shank portion intermediate the nail head and the textured portion and a resilient ring seated against the raised ring on the side of the raised ring opposite the nail head.
Another exemplary embodiment of the present invention includes a building structure comprising a building frame, one or more layers of stucco sheathing and a plurality of fasteners for securing a predetermined portion of the stucco sheathing to the building frame, wherein each fastener comprises a body of a predetermined axial length having a nail head at one axial end of the body, a textured portion at an opposite axial end of the body, and a shank portion extending between the nail head and the textured portion, wherein the shank portion has an axial length in excess of at least one-third of the axial length of the fastener body. The body further comprises a raised ring integrally formed in the shank portion intermediate the nail head and the textured portion and a resilient ring seated against the raised ring on the side of the raised ring opposite the nail head.
A further embodiment of the present invention includes a method of improving a lateral resistance of a stucco sheathing that is attached to a building frame. The method comprises providing a building frame and providing one or more layers of stucco sheathing. A plurality of stucco anchorage fasteners of the present invention are provided, wherein in each fastener comprises a body of a predetermined axial length having a nail head at one axial end of the body, a textured portion at an opposite axial end of the body, and a shank portion extending between the nail head and the textured portion, wherein the shank portion has an axial length in excess of at least one-third of the axial length of the fastener body. The body further comprises a raised ring integrally formed in the shank portion intermediate the nail head and the textured portion and a resilient ring seated against the raised ring on the side of the raised ring opposite the nail head. The plurality of fasteners are then installed to secure the stucco sheathing to the building frame.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawing wherein:
FIG. 1 is an elevation view of a stucco anchorage nail according to the present invention.
FIG. 2 is a partial perspective view of an exterior wall plate of a typical wood framing.
As shown in FIG. 2 , a typical building structure or structural frame 30 comprises a series of studs 32 such as 2×4 or 2×6 wooden studs, a sill plate 34 such as a wooden sill plate as well as window jambs and door jambs among other structures (not shown). The frame 30 is anchored to a building foundation 35 such as an on-grade concrete slab, by being anchored to the sill plate 34 , which is in turn anchored to the foundation 35 by bolts. Insulation 36 is typically disposed between the studs 32 to thermally “proof” the structure 30 .
Building paper 38 such as waterproof building paper and a metal lathe or wire mesh 40 are generally attached to the frame 30 by fasteners, according to the present invention before a stucco sheathing 42 is applied over the wire mesh 40 as an exterior finish to the frame 30 . The wire mesh 40 is secured by fasteners 44 . Typically, the stucco sheathing 42 is applied over the wire mesh 40 such that bonding occurs between the stucco sheathing 42 and the wire mesh 40 . The stucco sheathing 42 may be applied in several coats such as three coats
A drip screed 37 may be installed between the building 30 and stucco sheathing 42 , for example, at the base of the frame 30 . The drip screed 37 helps prevent moisture from entering the junction at the bottom of the frame 30 and the foundation 35 .
DETAILED DESCRIPTION
A nail 10 according to the present invention is shown in FIG. 1 in a side elevation view. The nail comprises a shank portion 12 and a textured portion 14 . Nail 10 has a nail head 15 located at one axial end of the nail and a pointed tip 16 at the opposite axial end of the nail. Shank portion 12 comprises an upper portion 18 and a lower portion 20 . A raised ring or circular ridge 22 is integrally formed with shank portion 12 approximately in the center of shank portion 12 . The ring or ridge 22 forms a second head on the nail 10 which has a diameter slightly smaller than the outside diameter of head 15 . Seated against ring 22 is a disk 24 of a resilient material which is fitted onto lower shank portion 20 and seated against the side of ring 22 opposite head 15 . Shank upper and lower shank portions 18 , 20 have a smooth surface. Textured portion 14 is provided with a spiral texture or ring shank texture extending from the end of lower shank portion 20 to tip 16 . In an exemplary embodiment of the invention, the stucco anchorage nail is a double-headed nail having a 0.162 inch diameter shank. The diameter of head 15 is 9/32 of an inch and its axial thickness dimension is 1/16 of an inch. Ring 22 is spaced approximately 2 inch from head 15 and is ¼ inch in diameter and 1/16 inch thick. The stucco anchorage nail according to the present invention has an overall length of 22 inches with the textured portion 14 being 12 inches in length. The length of the tip from the end of the texture to the pointed tips 16 is 3/16 of an inch and the ring 22 is located 2 inch from the beginning of the textured portion 14 .
The resilient ring 24 in an exemplary embodiment is ⅛ of an inch thick with a ⅜ inch outside diameter and a 3/16 inch inside diameter. As indicated previously, the resilient ring is preassembled and fitted onto the nail and seated against ring 22 before the nail is used. In an exemplary embodiment, ring 24 is a neoprene washer.
In new construction, the stucco anchorage nail according to the present invention is driven into the drip screed and the wood framing typically at 8 inches on center intervals. The spiral or ring shank texture on portion 14 is driven through the wood framing and the texturing threading enables the nail to resist pullout when subjected to lateral forces. In use, the nail is driven through the drip screed which overlies the mud sill on wood frame construction and penetrates the drip screed and extends approximately ½ inch into the framing. The ring 22 and ring 24 assembly is driven against the building paper overlay which is applied over the framing and the drip screed and the ring 24 is tightly seated against the paper and the drip screed. The provision of resilient ring 24 such as a neoprene washer minimizes moisture intrusion around the nails and into the framing and the flooring.
The structure of the nail means that approximately ½ inch of the nail protrudes from the drip screed to the exterior of the structure and this ½ inch projection from the drip screed permits a typical ⅜ inch thick stucco scratch coat to be applied by a plasterer with minimal interference such that the scratch coat fills in most of the space along upper shank portion 18 leaving the head 15 protruding from the scratch coat after said coat has been applied. A second coat of plaster, called brown coat, which is ¼ inch thick is then applied covering head 15 of the nail. A finish or color coat is then applied to complete the stucco sheathing. The smooth lower shank portion 20 of the nail below rings 22 and 24 facilitates the bearing of full loads on the first ½ inch penetration of the nail into the wood mud sill and other wood frame members.
In fabrication, the exemplary embodiment of the invention is to heat treat the nail after it has been fabricated. The heat treating of the nails provides ductility to the nails which enhances their flexibility and strength during the lateral back and forth motion imposed on the nail during earthquake and hurricane lateral forces. After heat treating the nail is hot-dipped galvanized to resist corrosion from moisture that can accumulate at the bottom of the stucco between the back face of the stucco and the building paper backing.
The present invention addresses the need demonstrated by tests of conventionally attached stucco sheathing that failed at the sill plate, with and without drip screeds. The failures were similar to the resulting damage during past earthquakes. Failure occurred at lateral displacements between ⅜ inch and ¾ inch, very similar to drywall. A better connection is produced between the stucco and the wood sill plate by the stucco anchorage nail of the present invention, a special heat treated nail by 2½ inches long, with a double head that projects ½ inch into the stucco, to develop shear resistance. The nail has a neoprene rubber ring or grommet under the second head to seal the nail hole at the face of the building paper. A 1½ inch length of the nail at the pointed end has a ring shank or spiral textured treatment to prevent pull-out of the nail as the panel is racked by lateral forces. Heat treating the nails after fabrication provides a more flexible nail to enhance the cyclic performance of the stucco. To reduce diagonal cracks that typically occur at the corners of openings, such as doors and windows, a flat 4 inch wide by 24 inch long strip of expanded metal lath is pressed diagonally at each opening corner into the initial ⅜ inch thick stucco scratch coat immediately after troweling.
The nail of the present invention is spaced to provide desired stucco shear resistance at the sill plate, panel edges and at jambs toward developing the potential 1,000 pounds per foot yield limit shear value of stucco and integral wire netting.
In summary, the present invention provides an inexpensive device and method for improving a building structure's resistance to earthquake and/or hurricane forces. This reduces structural damage to the building structure's stucco sheathing, interior wall sheathing and prolongs the occupancy of wood framed structures.
The preceding description has been presented with reference to certain embodiments of the invention. Workers skilled in the art and technology to which this invention pertains will appreciate that alterations and changes in the described structure may be practiced without meaningfully departing from the principal, spirit and scope of the invention. Accordingly, the foregoing description should not be read as pertaining only to the precise structures described and illustrated in the accompanying drawings, but rather should be read consistent with and as support to the appended claims which are to have their fullest and fair scope. | A fastener including a body having a predetermined axial length, wherein the body includes a nail head at one axial end of the body, a textured portion at an opposite axial end of the body, a shank portion extending between the nail head and the textured portion, and wherein the shank portion has an axial length in excess of at least one-third of the axial length of the fastener body, a raised ring integrally formed in the shank portion intermediate the nail head and the textured portion and a resilient ring seated against the raised ring on the side of the raised ring opposite the nail head. | 5 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present invention relates to a recorded medium feeding device that feeds a recorded medium to a recording unit that carries out recording on the recorded medium and a recording apparatus having the same.
[0003] 2. Related Art
[0004] A feeding roller that feeds paper in the paper feeding device is generally provided at a position deviated toward the side of a reference position (the single-digit side) in the direction of paper width in order to accommodate paper in small sizes. Therefore, when feeding paper in a large size, the feed roller is positioned so as to be deviated toward the single-digit side with respect to the widthwise center position of the paper. However, the curved posture of the paper at a position of the feed roller is different from the curved posture at a position apart from the feed roller, and hence paper skew is resulted. Therefore, in the paper feeding device disclosed in Japanese Patent No. 3775492, an “auxiliary roller” having substantially the same shape as the feed roller when viewing the paper feed path from the side is provided so that the curved posture of paper is uniformized in the direction of paper width.
[0005] There is a paper-feeding device of a type which feeds paper from the paper-feed cassette by a pickup roller invert the paper by an intermediate roller provided on the downstream side of the pickup roller and feeds the inverted paper to the recording unit. In the paper feeding device of this type, the pickup roller is provided at a position deviated to the side of the reference position (the single-digit side) in the direction of paper width for accommodating paper in smaller sizes. Therefore, in the paper feeding device in this manner, means for constraining the curved posture of the paper to be uniform in the direction of paper width is preferable in the same manner as described above.
[0006] In the paper feeding device of this type, separating means for separating paper on the downstream side of the pickup roller is provided. The separating means separates a piece of paper to be fed and subsequent pieces of paper by forming a nip point between the feed roller and the retard roller.
[0007] Since the separating means provides a paper-passage load to the paper, the pickup roller and the separating means are provided at substantially the same position in the direction of paper width. However, the paper to be fed receives the paper-passage load from the separating means, the speed of paper when passing through the separating means is lower than the paper feeding speed by the pickup roller, and hence the paper tends to be skewed between the pickup roller and the separating means as a result.
[0008] In other words, in the direction of paper width, the length of the paper path at the position of the pickup roller and the separating means in the direction of paper width is longer than the length of the paper path at a position apart from the pickup roller and the separating means, which may cause the paper skew. Therefore, in the paper feeding device of this type, it is not possible to prevent the paper skew only by providing the “auxiliary roller” which has substantially the same shape as the paper feeding roller when viewing the paper feeding path from the side as described in Japanese Patent No. 3775492.
SUMMARY
[0009] An advantage of some aspects of the invention is that occurrence of paper skew in a paper feeding device configured to feed paper by a pickup roller and separate the paper by separating means provided on the downstream side.
[0010] According to an aspect of the invention, there is provided a recorded medium feeding device including: a pickup roller that comes into contact with the recorded medium and rotates to feed recorded medium from a setting position toward the downstream side; and a separating means for separating a recorded medium to be fed and subsequent recorded media from the next page onward by forming a nip point for nipping the recorded medium on the downstream side of the pickup roller, in which the positions of the nip point of the separating means and the place where the pickup roller comes into contact with the recorded medium in the direction orthogonal to the recorded medium feeding direction with respect to a recorded medium of a predetermined size to be fed by the pickup roller are located within a range deviated to one side from the center position of the recorded medium of the predetermined size, and a path elongating portion that elongates the feed path length of the recorded medium to a length longer than the feed path length at a place where the pickup roller comes into abutment with the recorded medium by coming into abutment with the recorded medium is provided at a position apart from the nip point of the separating means and the place where the pickup roller comes into contact with the recorded medium toward the other side.
[0011] Accordingly, since the path elongating portion is provided at a position apart from the pickup roller in the direction orthogonal to the direction of feeding the recorded medium for extending the feed path length at the position, the difference in feed path length at the position apart from the pickup roller is reduced or is eliminated even when the recorded medium is skewed between the pickup roller and the separating means and the feed path length at the position of the pickup roller is increased, so that the skew of the recorded media is prevented.
[0012] Preferably, the path elongating portion is provided on a pivotal member which is able to pivot and rotatably supports the pickup roller.
[0013] Accordingly, since the path elongating portion is provided on the pivotal member which is able to pivot and rotatably supports the pickup roller, the structure of configuration that the position to come into contact with the recorded medium is displaced according to the amount of stacked recorded media is simplified at a low cost.
[0014] Preferably, the path elongating portion is provided so as to be capable of displacing the position on the pivotal member or so as to be capable of changing its own posture, so that the feed path length is elongated by coming into contact with the recorded medium fed by the pickup roller.
[0015] In a case in which the path elongating portion is provided fixedly with respect to the pivotal member, when the posture of the pivotal member is changed according to the stacked amount of recorded media, there arises a case in which the path elongating portion cannot come into contact with the recorded medium and hence the feed path length cannot be elongated. However, according to the aspect of the invention, the path elongating portion is provided not fixedly with respect to the pivotal member so as to be capable of changing the position with respect to the pivotal member, or so as to be capable of changing the posture of its own. Therefore, since the length of the feed path is elongated in a state of being in contact with the recorded medium irrespective of the posture of the pivotal member, the skew of the recorded medium is adequately prevented irrespective of the stacked amount of the recorded medium.
[0016] According to another aspect of the invention, there is provided a recording apparatus including a recording unit that carries out recording on the recorded medium, and the recorded medium feeding device as described above that feeds the recorded medium to the recording unit. Accordingly, the same effects and advantages as described above are achieved in the recording apparatus.
[0017] According to another aspect of the invention, there is provided a liquid ejecting apparatus including: a pickup roller that feeds ejected medium from a setting position toward the downstream side by coming into contact with the ejected medium and rotating; a separating means for separating a ejected medium to be fed and subsequent ejected media from the next page onward, and a liquid ejecting unit for ejecting liquid to an ejected medium, in which the positions of the nip point of the separating means and the place where the pickup roller comes into contact with the recorded medium in the direction orthogonal to the ejected medium feeding direction with respect to an ejected medium of a predetermined size to be fed by the pickup roller are located within a range deviated to one side from the center position of the ejected medium of the predetermined size, and a path elongating portion that elongates the feed path length of the ejected medium to a length longer than the feed path length at a place where the pickup roller comes into abutment with the ejected medium by coming into abutment with the ejected medium is provided at a position apart from the nip point of the separating means and the position where the pickup roller comes into contact with the ejected medium toward the other side.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention will be described with reference to the accompanying drawings, wherein like numbers reference like elements.
[0019] FIG. 1 is a schematic side cross section of a printer according to an embodiment of the invention.
[0020] FIG. 2 is a plan view of a principal portion of a feeding device according to the embodiment of the invention.
[0021] FIG. 3 is a perspective view of the feeding device according to the embodiment of the invention.
[0022] FIG. 4 is a side view of a path elongating portion in the feeding device according to the embodiment of the invention.
[0023] FIG. 5 is a front view of a pivotal member in the feeding device according to the embodiment of the invention.
[0024] FIG. 6 is a perspective view of the path elongating portion according to another embodiment.
[0025] FIG. 7 is a side view of the path elongating portion according to another embodiment of the invention.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0026] Referring now to drawings, an embodiment of the invention will be described. FIG. 1 is a schematic side cross-section of an ink jet printer (hereinafter, referred to as “printer”) according to an embodiment of a “recording apparatus” or a “liquid ejecting apparatus” according to the invention; FIG. 2 is a plan view of a principal portion of a front feeding device 3 ; FIG. 3 is a perspective view of the front feeding device 3 in FIG. 2 ; FIG. 4 is a side view of a path elongating portion 26 ; and FIG. 5 is a front view of a pivotal member 23 .
[0027] In the description shown below, a general configuration of the printer 1 will be described in brief on the basis of FIG. 1 . The printer 1 includes a rear feeding device 2 as first paper feeding means at a rear portion thereof and a front feeding device 3 according to the invention at a bottom thereof as second paper feeding means, and feeds recording paper (mainly cut paper; hereinafter, referred to as “paper P”) as “recorded media” or “ejected media”. The paper P is transported to a recording unit 4 by a transport means 5 and is discharged to a stacker, not shown, by discharge means 6 .
[0028] Components on the paper transport path will be described further in detail.
[0029] The rear feeding device 2 includes a hopper 12 , a feed roller 11 , a retard roller 13 and a paper-return lever 14 . The hopper 12 pivots about a pivotal movement support 12 a at the upper portion thereof to switch between a posture to bring the paper P supported on the hopper 12 in an inclined posture into press contact with the feed roller 11 , and a posture to bring the same from the feed roller 11 .
[0030] The retard roller 13 is provided in a state of being applied with a predetermined rotational resistance, and separates a paper P to be fed at an uppermost position and a subsequent paper P from the next page onward by forming a nip point with the feed roller 11 . The paper-return lever 14 is rotatably provided when viewing the paper feeding path from the side, and rotates to return the paper P from the second page onward separated by the retard roller 13 .
[0031] On the other hand, the front feeding device 3 provided on the bottom portion of the printer 1 and configured to set the paper from the front thereof includes a paper feed cassette 20 , a pickup roller 22 , intermediate rollers 24 , a retard roller 21 , a paper return lever 28 and assist rollers 25 .
[0032] A plurality of pieces of paper P may be set in a stacked state on the paper feed cassette 20 which is capable of mounting and demounting from the front side thereof, and the uppermost one of the set paper P is fed from the paper feed cassette 20 (set position) one by one by the pickup roller 22 driven by the drive motor, not shown. The pickup roller 22 is provided on a pivotal member 23 which pivots about a pivotal movement axis 17 , and switches a state of coming into contact with the uppermost paper P and a state of moving apart from the uppermost paper P by a pivotal movement of the pivotal member 23 as shown by a solid line and a virtual line in FIG. 1 . A high-friction pad 18 is provided on a bottom surface of the paper feed cassette 20 is (see FIG. 3 and FIG. 4 ), so that a bundle of paper from the second page onward is prevented from being fed downstream in association with a paper feeding operation by the pickup roller 22 .
[0033] The paper P to be fed from the set position by the pickup roller 22 is preliminarily separated by moving ahead from a leasing edge thereof toward the downstream side while being in sliding contact with an inclined surface for separation (sliding contact surface) 20 a , and then moves ahead to the retard roller 21 which constitutes the separating means. The retard roller 21 is provided at a position opposing outer peripheral surfaces of the intermediate rollers 24 , and is provided so as to be capable of moving forward and backward with respect to the intermediate rollers 24 . When the paper is fed from the paper feed cassette 20 , the uppermost paper P to be fed is separated from the paper P from the second level (second page) onward by coming into a press contact with the intermediate rollers 24 and forming a nip point.
[0034] The paper return lever 28 is provided so as to be rotatable when viewing the paper feed path, and returns the paper P from the second page onward separated by the retard roller 21 toward the upstream side (paper feed cassette 20 ).
[0035] The intermediate rollers 24 are driven by a drive motor, not shown, incurvates and inverts the paper to be fed, and feeds the same to the transport means 5 . The assist rollers 25 come into contact with the intermediate rollers 24 to assist feeding of the paper P by the intermediate roller 24 toward the downstream side.
[0036] Subsequently, the transport means 5 provided on the downstream side of the rear feeding device 2 and the front feeding device 3 includes a transport drive roller 31 which rotates by being driven by a motor, and a transport driven roller 32 which is rotated by coming into press contact with the transport drive roller 31 . The paper P which reaches the transport means 5 is transported to the recording unit 4 on the downstream side by the rotation of the transport drive roller 31 in a state in which the paper is nipped between the transport drive roller 31 and the transport driven roller 32 .
[0037] The recording unit 4 includes a recording head 38 for discharging ink toward the paper P and a paper guide front 35 for constraining the distance of the paper P and the recording head 38 by supporting the paper P. The recording head 38 is provided on a bottom portion of the carriage 36 , and the carriage 36 is driven so as to reciprocate in the primary scanning direction by the drive motor, not shown while being guided by a carriage guide shaft 37 extending in the primary scanning direction (the direction through the front and back surfaces of the paper of the drawing). The carriage 36 includes ink cartridges (not shown) independent for a plurality of colors, so that ink is supplied from the ink cartridges to the recording head 38 .
[0038] Subsequently, the discharge means 6 for discharging the paper P after having printed thereon on the downstream side of the recording unit 4 . The discharge means 6 includes a discharge drive roller 39 rotated by being driven by a motor, not shown and a discharge driven roller 40 that rotates by being driven by coming into contact with the discharge drive roller 39 . The paper P after having recorded by the recording unit 4 is discharged onto a stacker, not shown, provided on the front side of the apparatus by the discharge drive roller 39 which rotates by being driven in a state in which the paper P is nipped between the discharge drive roller 39 and the discharge driven roller 40 .
[0039] The printer 1 has been briefly described thus far. Referring now to FIG. 2 and FIG. 5 , the front feeding device 3 will be described further in detail.
[0040] The paper feed cassette 20 is provided with a movable edge guide 19 so as to be displaceable in the direction of paper width (lateral direction in FIG. 2 ), and constrains side edges of the paper set in the paper feed cassette 20 together with an inner wall surface 20 b in the interior of the paper feed cassette 20 . The inclined surface for separation 20 a is formed at apposition opposing the leading edge of the paper set in the paper feed cassette 20 , and the paper fed from the set position by the pickup roller 22 moves ahead while being in sliding contact at the leading edge thereof with the inclined surface for separation 20 a , thereby being separated preliminarily from the paper from the second page onward.
[0041] The pickup roller 22 and the retard roller 21 are provided in an area deviated from the center position of a paper storage area of the paper feed cassette 20 (the position indicated by a reference sign C 1 ) to the one side (one-digit side (the side of the reference position): right side in FIG. 2 ) in the direction orthogonal to the paper feed direction (the lateral direction in FIG. 2 ; hereinafter, referred to as “direction of the paper width).
[0042] In other words, the pickup roller 22 and the retard roller 21 are positioned at places deviated from the widthwise center position to the single-digit side for relatively large sized paper (for example, A4 paper) from among various sizes of paper which can be set in the paper feed cassette 20 .
[0043] In contrast, the pickup roller 22 and the retard roller 21 are positioned at places deviated from the widthwise center position to the 80-digit side (left side in FIG. 2 ) for relatively small sized paper (for example, post-card sized paper). Depending on the size, the pickup roller 22 and the retard roller 21 are positioned at the widthwise center position. In this embodiment, the positions of the pickup roller 22 and the retard roller 21 in the direction of the paper width are the same.
[0044] Subsequently, the pickup roller 22 is provided on the pivotal member 23 formed substantially into an L-shape which is pivotal about the pivotal movement axis 17 . The pivotal member 23 is integrally provided with an arm portion 23 a extending in the direction of paper width by resin material, and the arm portion 23 a is positioned above a position where the pickup roller 22 comes into contact with the paper in plan view as shown in FIG. 5 , thereby forming a shoulder 23 c.
[0045] With the provision of the shoulder 23 c , even when the paper assumes a curled so as to project downward in the stacked state as shown by a reference sign P E , the side portion of the paper is released to the pivotal member 23 c , so that a contact of the pickup roller 22 with the stacked paper is ensured. The shoulder 23 c is provide with a roller 27 , so that the side end of the paper comes into contact with the roller 27 so that smooth feeding of the paper is achieved.
[0046] A path elongating portion 26 is integrally formed with the arm portion 23 a at the distal end of the arm portion 23 a . The path elongating portion 26 is arranged at a position apart from the positions of the pickup roller 22 and the retard roller 21 toward the other side (the 80 digit side; left side in FIG. 2 ) in the direction of the width as shown in FIG. 2 , and has a shape projecting in the paper feeding direction with respect to the pickup roller 22 when viewing the paper feed path from the side as shown in FIG. 4 .
[0047] As shown in FIG. 4 , a reference sign P (solid line) shows a posture of a paper (paper feed path) at the position of the path elongating portion 26 , and as apparent from the comparison with the posture of the paper (paper feed path) indicated by the reference sign P′ (virtual line), the length of the paper feed path at the position of the path elongating portion 26 is elongated by the provision of the path elongating portion 26 .
[0048] Accordingly, the following effects and advantages are achieved. That is, since the paper to be fed receives a load when passing through the nip point between the retard roller 21 and the intermediate rollers 24 , when comparing the speed of paper when passing through the retard roller 21 and the paper feeding speed by the pickup roller 22 , the former is lower, and the paper to be fed is bent between the pickup roller and the retard roller 21 as if it is pressed against the inclined surface for separation 20 a . In other words, the paper feed length at the positions of the pickup roller 22 and the retard roller 21 is elongated by the paper separation by the retard roller 21 and the intermediate rollers 24 .
[0049] Therefore, by the provision of the path extending portion 26 , the difference between the paper path length at a position apart from the pickup roller 22 and the retard roller 21 and the paper path length at positions of the both rollers is reduced, or the path difference is eliminated, so that the paper skew is prevented.
[0050] Subsequently, referring to FIG. 6 and FIG. 7 , another embodiment will be described. FIG. 6 is a perspective view of a path elongating portion 260 according to another embodiment. FIG. 7 is a side view thereof.
[0051] The path elongating portion 260 is provided so as to be capable of changing the posture of the pivotal member 23 , so that the feeding path is elongated by coming into contact with the paper which is fed by the pickup roller 22 irrespective of the posture of the pivotal member 23 .
[0052] More specifically, the path elongating portion 260 is provided so as to be capable of pivoting about a pivotal shaft 260 a when viewing the feed path from the side. A coil spring 270 is inserted into the pivotal shaft 260 a , one end 270 a of the coil spring 270 is hooked on a spring hooking portion 260 b formed on the path elongating portion 260 , and the other end 260 of the pivotal member 23 , and the other end 270 b is hooked on the spring hooking portion 23 b of the pivotal member 23 , so that the distal end of the path elongating portion 260 is urged toward the paper.
[0053] In FIG. 7 , a state in which the amount of stacked paper is large (the state in which the maximum amount of paper is stacked) is shown by (A) and a state in which the amount of stacked paper is small (the state in which the minimum amount of paper (one) is stacked) is shown by (B) and both states are drawn in the same drawing for easy comparison.
[0054] In the state (B) in FIG. 7 in which the amount of stacked paper is small, since the angle between the set paper and the pivotal member 23 is relatively steep, the path elongating portion 260 comes into contact with the paper in the state of being pivoted clockwise in the drawing against the urging force of the coil spring 270 .
[0055] Assuming that the path elongating portion 260 is fixedly provided with respect to the pivotal member 23 so as not to change in posture and keep the state of (B) in FIG. 7 , when the amount of stacked paper is increased, the angle formed between the set paper and the pivotal member 23 is relatively gentle as shown by a virtual line in (A), so that the distal end of the path elongating portion 260 cannot come into contact with the paper between the intermediate rollers 24 and the pickup roller 22 and hence the feed path length cannot be elongated.
[0056] However, since the path elongating portion 260 is provided on the pivotal member 23 so as to be capable of changing in posture, the path elongating portion 260 comes into contact with the paper fed by the pickup roller 22 and elongates the feed path as shown by a solid line in (A) in FIG. 7 . Therefore, the paper skew may be prevented adequately irrespective of the amount of stacked paper.
[0057] In the embodiment shown above, the path elongating portion 260 is provided on the pivotal member 23 so as to be capable of pivoting with respect to the pivotal member 23 , that is, so as to be capable of changing in posture, so that the path elongating portion 260 comes into contact with the paper fed by the pickup roller 22 and elongates the feed path length. However, it is also possible to provide the path elongating portion 260 in such a manner that the position with respect to the pivotal member 23 is displaceable so that the path elongating portion 260 comes into contact with the paper fed by the pickup roller 22 and elongate the feed path length. For example, by providing the path elongating portion 260 so as to be displaceable in the vertical direction in FIG. 7 and urging the same in the direction to come into contact with the paper, the path elongating portion 260 is able to come into contact with the paper fed by the pickup roller 22 irrespective of the posture of the pivotal member 23 . | A recorded medium feeding device includes a pickup roller that feeds recorded medium dowstream from a setting position by contacting with the recorded medium and rotating and a separating means for separating recorded medium to be fed and subsequent recorded media from the next page onward. The positions of a nip point of the separating means and a place where the pickup roller contacts the recorded medium in the direction orthogonal to the recorded medium feeding direction with respect to a recorded medium of a predetermined size to be fed by the pickup roller are located within a range deviated to one side from the center of the recorded medium of the predetermined size. A path elongating portion that elongates the feed path length of the recorded medium by abutting the recorded medium is apart from the nip point and the place where the pickup roller contacts the recorded medium. | 1 |
INCORPORATION BY REFERENCE
The present application claims priority from JP Patent Application Ser. No. 2009-209173 filed on Sep. 10, 2009, the content of which is hereby incorporated by reference into this application.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to a sliding bearing for an internal combustion engine in which a pair of semi-cylindrical bearings is combined with each other into a cylindrical shape to support a crankshaft.
(2) Description of the Related Art
Conventionally, a sliding bearing formed into a cylindrical shape by combining two semi-cylindrical bearings is used for a crankshaft. A circumferential oil groove is formed on a bearing inner surface of at least one of a pair of semi-cylindrical bearings, and oil is supplied to an outer circumferential surface of a crankpin via the circumferential oil groove (see JP-A-8-277831).
Meanwhile, in recent years, in order to decrease the leakage amount of lubricant oil from the bearing end portion in response to reduction in size of oil pump for supplying the lubricant oil, it has been proposed to form a narrowed portion in which the sectional area of the oil groove is reduced toward the end portion of the bearing from the bearing central portion, and to remove a crush relief by forming a circumferential oil groove machined by boring on an inner surface of the circumferential end portion of the bearing (see JP-A-2005-69283 and JP-A-2002-188624).
Also, in order to discharge foreign matters accompanying the lubricant oil and entering the sliding surface of the bearing, a bearing is proposed in which a clearance for discharging the foreign matters is formed on the inner surface of the both circumferential end portions of semi-cylindrical bearing (see JP-A-2005-69283 and JP-A-2008-82355).
BRIEF SUMMARY OF THE INVENTION
With regard to supply of lubricant oil to a sliding bearing for an internal combustion engine, the lubricant oil is first supplied from an outside of the sliding bearing for the crankshaft into the circumferential oil groove which is formed on the inner surface of the sliding bearing for the crankshaft. Next, the lubricant oil is supplied to the sliding surface of the sliding bearing for the crankshaft, and the sliding surface of a sliding bearing for a crankpin.
At the time of the initial operation of an internal combustion engine, foreign matters remaining in the lubricant oil path tend to enter the lubricant oil which is supplied to the circumferential oil groove of the sliding bearing for the crankshaft. The foreign matters mean metalwork chippings produced during the cutting work of the oil path, molding sand used in casting process, and the like. Foreign matters accompany the flow of the lubricant oil due to the rotation of the crankshaft. In the conventional sliding bearing for an internal combustion engine, foreign matters are discharged to the outside of the bearing together with the lubricant oil through clearance portions in a crush relief, a chamfer, and the like which are formed at the circumferential end portion of the bearing. However, since the rotational speed of the crankshaft in the internal combustion engines has been increased recently, the inertia force becomes large which acts on the foreign matters having specific gravities larger than that of the lubricant oil (foreign matters move forward along the circumferential direction by the inertia force). Therefore, the foreign matters are not discharged from the clearance portion in the combined end surfaces of the sliding bearing (combined end surfaces of a pair of semi-cylindrical bearings), and enter the sliding surface of the sliding bearing (the other semi-cylindrical bearing) which does not have an oil groove. This increases the possibility of damage of the bearing sliding surface due to the foreign matters.
Meanwhile, sliding bearings are proposed in which a narrowed portion is formed in the oil groove in the circumferential end portion of a semi-cylindrical bearing, in order to decrease the leakage amount of the lubricant oil from the circumferential end portion of the bearing (see JP-A-2005-69283). Studying these sliding bearings from the viewpoint of the aforementioned foreign matters, there is the problem that the flow velocity of the lubricant oil increases at the downstream of the narrowed portion with respect to the flowing direction of the lubricant oil, and then the aforementioned inertia force which acts on the foreign matters accompanying the lubricant oil becomes larger correspondingly, and this further increases the possibility of the entry of the foreign matters to the bearing sliding portion of the other semi-cylindrical bearing in which the oil groove is not formed.
Thus, an object of the present invention is to provide a sliding bearing for an internal combustion engine, which is excellent in capability of discharging foreign matters.
In view of the above described object, according to the present invention, there is provided a sliding bearing for an internal combustion engine for supporting a crankshaft, composed of a pair of semi-cylindrical bearings combined with each other into a cylindrical body to support a crankshaft, a circumferential oil groove being formed to extend in a circumferential direction on an inner circumferential surface of one of the semi-cylindrical bearings. Each of inner circumferential surfaces of the respective semi-cylindrical bearings includes first and second curved surfaces following two kinds of arcs with different curvatures. The first curved surface is in a region including a circumferential central portion of the inner circumferential surface. The second curved surfaces are in remaining two regions of the inner circumferential surface which connect to the first curved surface region and extend toward both circumferential ends of the semi-cylindrical bearing. A relationship of a center (C 1 ) of a first arc which forms the first curved surface and a center (C 2 ) of a second arc which forms the second curved surface is such that the center (C 2 ) of the second arc is located on a perpendicular line to a bearing bore diameter center line passing through the center (C 1 ) of the first arc, and is located outside from the center (C 1 ), that is, is located at a position displaced to a side of the semi-cylindrical bearing which is a counterpart to be combined. The second curved surfaces are formed in a region in which a circumferential angle (θ) is between 20° at a minimum value and 50° at a maximum value. The circumferential angle (θ) is measured from a circumferential end surface of each of the semi-cylindrical bearings with the center (C 1 ) of the first arc as a center. The inner circumferential surface comprising the first and the second curved surfaces is a sliding surface in which a number of microscopic circumferential grooves are formed. The groove depths of the circumferential grooves of the second curved surfaces are larger than the groove depths of the circumferential grooves of the first curved surface. A bearing wall thickness (W 1 ) in the circumferential central portion of the semi-cylindrical bearing is larger than a bearing wall thickness (W 2 ) in a circumferential end portion. An axial groove for a lubricant oil extending over an entire width of the sliding bearing exists along both butted end surfaces of the pair of semi-cylindrical bearings which are combined into a cylindrical shape. The circumferential oil groove and the axial groove communicate with each other. A cross-sectional area of the circumferential oil groove in the communication portion is larger than a cross-sectional area of the axial groove. The circumferential grooves of the second curved surfaces and the axial groove communicate with each other. The groove depths of the circumferential grooves of the second curved surfaces and the axial groove in the communication portion are different from each other. The groove bottoms of the circumferential grooves of the second curved surfaces are displaced to a side of the bearing inner circumferential surface from a groove bottom of the axial groove. The axial groove is defined by a slant surface extending from the inner circumferential surface of at least one semi-cylindrical bearing of the pair of the semi-cylindrical bearings to the circumferential end surface.
The foreign matters which accompany the lubricant oil and enter the circumferential oil groove reach the end portion of the circumferential oil groove located at the position in the same direction as the relative rotational direction of the crankshaft by the lubricant oil flow in the circumferential oil groove by rotation of the crankshaft. However, when the axial groove which is the discharge passage for the foreign matters does not exist at the circumferential end portion of the semi-cylindrical bearing (JP-A-2002-188624), the foreign matters reach the inner circumferential surface of the other semi-cylindrical bearing, which is the combination counterpart and is located beyond the end portion of the circumferential oil groove. As a result, the foreign matters are locally embedded and accumulated in the inner circumferential surface.
Further, even if the axial groove for discharging foreign matters is formed in the circumferential end portion of the semi-cylindrical bearing, the open portion of the end portion of the circumferential oil groove is closed by the circumferential end surface of the other semi-cylindrical bearing which does not form the circumferential oil groove. Therefore, the foreign matters float and approach the crankshaft surface, and thereafter, enter the axial groove. However, before some of the aforementioned floating foreign matters enter the axial groove, they are forced to flow by the lubricant oil flow in the circumferential direction in the vicinity of the crankshaft surface, and reach the inner circumferential surface of the other semi-cylindrical bearing, which is the combination counterpart located and is located beyond the end portion of the circumferential oil groove. Then, they are locally embedded and accumulated in the inner circumferential surface. When local embedment and accumulation of the foreign matters occurs in the inner circumferential surface of the bearing, there arises the fear that the foreign matters and crankshaft are brought into contact with each other to generate heat and cause seizure.
According to the present invention, such a problem of the related art can be solved.
More specifically, the semi-cylindrical bearing is configured such that each of inner circumferential surfaces of a pair of semi-cylindrical bearings is constituted of first and second curved surfaces following two kinds of arcs with different curvatures, the first curved surface is in a region including a circumferential central portion of the aforementioned inner circumferential surface, and the second curved surfaces connect to the first curved surface region and extend toward both circumferential ends of the semi-cylindrical bearing. Therefore, the lubricant oil and some of the foreign matters in the circumferential oil groove tend to be also dispersed and flow into a gap formed by the second curved surface and the crankshaft surface. Therefore, the phenomenon apt to be occurred in the related art can be suppressed that the foreign matters reach the inner circumferential surface of the semi-cylindrical bearing, which is the combination counterpart located beyond the end portion of the circumferential oil groove, and are locally embedded and accumulated in the inner circumferential surface.
A number of microscopic circumferential grooves are usually formed on the inner circumferential surface of the bearing composed of the second curved surface. The lubricant oil which is dispersed and flows into the gap made by the second curved surface and the crankshaft surface and the foreign matters accompanying the lubricant oil are guided to the circumferential grooves, and reach the circumferential end surface of the semi-cylindrical bearing. Therefore, the leakage amount of the lubricant oil from the gap formed by the second curved surface is small.
The second curved surface is formed so that a circumferential angle (θ) is between 20° at a minimum value and 50° at a maximum value. The circumferential angle (θ) is measured from a circumferential end surface of the semi-cylindrical bearing with the center (C 1 ) of the first arc as a center. If the circumferential angle (θ) measured from the circumferential end surface is less than 20°, the circumferential length of the second curved surface is small, and dispersion of the foreign matters in the circumferential oil groove into the gap portion is insufficient. If the circumferential angle (θ) exceeds 50°, the area of the first curved surface of the semi-cylindrical bearing which receives a large load by operation of the internal combustion engine becomes too small.
About the depths of a number of microscopic circumferential grooves which are formed on the aforementioned inner circumferential surface composed of the first and second curved surfaces, the groove depths of the circumferential grooves of the second curved surfaces are made larger than the groove depths of the circumferential grooves of the first curved surface.
In order to enhance the load capacity by facilitating oil film formation for the first curved surface which receives a large load by the operation of the internal combustion engine, the depths of the circumferential grooves of the first curved surface are preferably made smaller than the depths of the circumferential grooves of the second curved surface.
An axial groove for a lubricant oil extending all over the entire width of the sliding bearing exists along both butted end surfaces of a pair of semi-cylindrical bearings which are combined into a cylindrical shape. The circumferential oil groove, the circumferential grooves on the second curved surfaces and the axial groove communicate with one another. By this configuration, the foreign matters which flow out of the circumferential oil groove and the circumferential grooves on the second curved surfaces flow into the axial groove for the lubricant oil, and are discharged to the outside of the bearing.
In the communication portion of the circumferential oil groove and the axial groove, a cross-sectional area of the circumferential oil groove is made larger than a cross-sectional area of the aforementioned axial groove, and the flow velocity of the lubricant oil in the axial groove for the lubricant oil is high as compared with the flow velocity of the lubricant oil in the circumferential oil groove. Thus, the foreign matters hardly receive the influence of the flow of the lubricant oil flowing in the circumferential direction along the bearing inner circumferential surface with the rotation of the crankshaft. Therefore, the possibility is reduced that the foreign matters are forced out from the inside of the axial groove for the lubricant oil and move to the inner circumferential surface of the bearing, and thereby, enter the space between the sliding surfaces of the sliding bearing and the crankshaft.
Further, the circumferential grooves of the second curved surfaces and the axial groove for the lubricant oil communicate with each other. The groove depths of the circumferential grooves and the axial groove for the lubricant oil in the communication portion are different from each other. The groove bottoms of the circumferential grooves are displaced to a bearing inner circumferential surface side from the groove bottom of the axial groove for the lubricant oil. By the aforementioned configuration in which the groove depth of the axial groove for the lubricant oil is made large as compared with the groove depths of the circumferential grooves, the foreign matters which tend to move along the circumferential grooves directly enter the axial groove for the lubricant oil with a higher flow velocity of the lubricant oil as described above in the communication portion. Therefore, the foreign matters hardly receive the influence of the flow of the lubricant oil flowing in the circumferential direction along the inner circumferential surface of the bearing with rotation of the crankshaft. Therefore, the phenomenon apt to be occurred in the related art can be suppressed that the foreign matters reach the inner circumferential surface of the semi-cylindrical bearing, which is the combination counterpart located beyond the end portion of the circumferential oil groove, and are locally embedded and accumulated in the inner circumferential surface.
In a preferred embodiment of the present invention, the circumferential grooves of the second curved surface are formed to have groove depths of between 4 μm and 15 μm with pitches of between 0.1 mm and 0.8 mm, and the circumferential grooves of the first curved surface are formed to have groove depths of 3 μm or less with pitches of between 0.1 mm and 0.8 mm.
In order to guide the lubricant oil and foreign matters, which are dispersed into the gap portion made by the second curved surface and the crankshaft, to the axial groove for the lubricant oil, the circumferential grooves may be formed to have the groove depths of between 4 μm and 15 μm with pitches of between 0.1 mm and 0.8 mm. If the depths of the circumferential grooves are less than 4 μm and the pitches of the circumferential grooves (circumferential groove widths) are less than 0.1 mm, the lubricant oil and the foreign matters easily go out from the inside of the circumferential grooves. If the circumferential groove depths exceed 15 μm, and the pitches (circumferential groove widths) of the circumferential grooves exceed 0.8 mm, the cross-sectional area per one ridge in the vicinity of the apex of the crest portion of each of the circumferential grooves becomes too large, and when contact with the crankshaft occurs, the apex of the crest portion hardly wears to reduce conformability of the bearing.
The circumferential grooves of the first curved surface are made to have groove depths of 3 μm or less with pitches of between 0.1 mm and 0.8 mm. By the configuration, an oil film is easily formed on the first curved surface, and load capacity can be enhanced.
In another preferred embodiment of the present invention, a difference “W 1 -W 2 ” between the bearing wall thickness (W 1 ) in the circumferential central portion of the semi-cylindrical bearing and the bearing wall thickness (W 2 ) in the circumferential end portion is between 5 μm and 30 μm. If the aforementioned difference is less than 5 μm, the effect cannot be expected that the lubricant oil and foreign matters in the circumferential oil groove are dispersed and flow into the gap portion made by the second curved surfaces and the crankshaft. Further, if the aforementioned difference exceeds 30 μm, the leakage amount of the lubricant oil to the outside of the bearing from the gap portion made by the second curved surface and the crankshaft increases. In order to decrease the leakage amount of the lubricant oil from the aforementioned gap portion, the aforementioned difference is preferably 15 μm or less.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a front view of a semi-cylindrical bearing for supporting a crankshaft according to one embodiment of the present invention;
FIG. 2 is a view showing an inner circumferential surface of the semi-cylindrical bearing shown in FIG. 1 ;
FIG. 3 is a view showing an inner circumferential surface of the other semi-cylindrical bearing which is the counterpart of the semi-cylindrical bearing shown in FIGS. 1 and 2 ;
FIG. 4 is a view showing butted portions of a pair of semi-cylindrical bearings shown in FIGS. 1 to 3 together with a crankshaft at a location where a circumferential oil groove is present;
FIG. 5 is a schematic view locally showing the inner circumferential surfaces of a pair of semi-cylindrical bearings shown in FIG. 4 ; and
FIG. 6 is a view similar to FIG. 4 and showing the butted portions of a pair of semi-cylindrical bearings shown in FIGS. 1 to 3 together with the crankshaft at the location where the circumferential groove is present.
DETAILED DESCRIPTION OF THE INVENTION
Example
Hereinafter, an embodiment of the present invention will be described with reference to the attached drawings.
FIG. 1 is a view showing a semi-cylindrical bearing 10 for supporting a crankshaft of an internal combustion engine according to one embodiment of the present invention, which is shown from its axial direction. FIG. 2 is a view showing a bearing inner circumferential surface of the semi-cylindrical bearing 10 . The semi-cylindrical bearing 10 is combined with the other semi-cylindrical bearing 30 ( FIG. 3 ) in a substantially the same shape into a cylindrical shape to be a sliding bearing for a crankshaft. The difference between the both semi-cylindrical bearings 10 and 30 is that a circumferential oil groove 20 is formed in the central portion of the bearing width of the inner circumferential surface of the semi-cylindrical bearing 10 all over the entire length in the circumferential direction. The other structures of the both semi-cylindrical bearings 10 and 30 are not different from each other.
The bearing inner circumferential surface of the semi-cylindrical bearing 10 is formed by two kinds of arc surfaces with different curvatures. They are a first curved surface 16 located in a central region of the length in the circumferential direction of the bearing, and a second curved surfaces 18 which connect to both end portions in the circumferential direction of the bearing of the first curved surface 16 . The bearing inner circumferential surface of the semi-cylindrical bearing 30 is formed by a first curved surface 36 and second curved surfaces 38 , which are similar arc surfaces.
The semi-cylindrical bearing 10 will be described.
In FIG. 1 , the center of the arc surface of the first curved surface 16 is represented by C 1 , and the center of the arc surface of the second curved surface 18 is represented by C 2 . In FIG. 1 , a virtual straight line (X) passing through both circumferential end surfaces 12 and 14 of the semi-cylindrical bearing 10 is drawn, and a virtual straight line Y which is perpendicular to the virtual straight line X and bisects the circumferential length of the semi-cylindrical bearing 10 is drawn. The point of intersection of the virtual straight lines X and Y is the axial line position of the semi-cylindrical bearing 10 (sliding bearing), and is also the arc surface center C 1 of the first curved surface 16 . The first curved surface 16 is an arc surface with a radius RI with C 1 as the center. The arc surface center C 2 of the second curved surface 18 is on the virtual straight line Y, and is in the position displaced to the outside of the semi-cylindrical bearing 10 with respect to the arc surface center C 1 of the first curved surface 16 . The second curved surface 18 is the arc surface with a radius RII with C 2 as the center. The radius RII is larger than the radius RI.
Further, the second curved surfaces 18 are formed in the range in which a circumferential angle (θ) becomes between 20° at a minimum value and 50° at a maximum value. The center of the circumferential angle (θ) is C 1 , which is the axial line position of the semi-cylindrical bearing 10 and is also the arc surface center of the first curved surface 16 , and the measurement reference point of the circumferential angle (θ) is ether of the both circumferential end surfaces 12 and 14 of the semi-cylindrical bearing 10 .
The semi-cylindrical bearing 10 which is formed to have the above shape characteristics has such a shape that the wall thickness of the region corresponding to the second curved surface 18 gradually decreases toward the both circumferential end surfaces 12 and 14 with respect to a wall thickness (W 1 ) of the region corresponding to the first curved surface 16 to be a minimum wall thickness (W 2 ) at the positions of the end surfaces 12 and 14 . However, the following points should be noted with regard to the wall thickness (W 2 ).
Further, at the both circumferential end surfaces 12 and 14 of the semi-cylindrical bearing 10 , corner edge portions which are formed by the end surfaces 12 and 14 and the second curved surfaces 18 are removed by chamfering, and slant surfaces 12 a and 14 a are formed. In the case of the semi-cylindrical bearing 30 , corner edge portions formed by end surfaces 32 and 34 and the second curved surfaces 38 are removed by chamfering all over the entire width of the bearing, and slant surfaces 32 a and 34 a are formed.
As a result, an axial groove G with a V-shaped section extending over the entire length of the bearing width is defined in the butted portions of both of the semi-cylindrical bearings 10 and 30 , when the semi-cylindrical bearings 10 and 30 are combined into a cylindrical shape ( FIGS. 4 and 5 ).
The wall thickness (W 2 ) in the both circumferential end surfaces 12 and 14 of the semi-cylindrical bearing 10 is described above. However, when the slant surfaces 12 a and 14 a are formed at the portions of the end surfaces 12 and 14 , an accurate wall thickness cannot be actually measured. Accordingly, in the present description and claims, the wall thickness (W 2 ) is defined as the thickness on the assumption that the slant surfaces 12 a and 14 a are not formed and the corner edges exist.
[Function of the Axial Groove G]
In FIGS. 4 and 5 , the lubricant oil and accompanying foreign matters FM in the circumferential oil groove 20 move toward the circumferential end surface 14 with rotation of a crankshaft CR (rotational direction Z). In the circumferential end surface 14 , the axial groove G defined by the slant surfaces 14 a and 34 a exists, and the lubricant oil and the foreign matters FM flow into the axial groove G. At the location where the circumferential oil groove 20 communicates with the axial groove G, the cross-sectional area of the axial groove G is formed to be smaller than the cross-sectional area of the circumferential oil groove 20 . And then, the moving speed of the lubricant oil and the foreign matters FM which flow into the axial groove G becomes higher than the moving speed in the circumferential oil groove 20 . Therefore, the lubricant oil and the foreign matters FM mainly follow the flow in the axial groove G and are discharged to the outside of the bearing from the end surface portions in the bearing width direction.
Further, the second curved surface 18 has large radius of curvature as compared with the first curved surface 16 . A gap formed by the second curved surface 18 and the outer circumferential surface of the crankshaft CR is relatively large. Thus, the lubricant oil and accompanying foreign matters FM which flow in the circumferential oil groove 20 are dispersed and flow to the outside of the circumferential oil groove 20 , and are guided to a number of microscopic circumferential grooves 22 (work trace which is generated at the time of cutting work) which are present on the second curved surface 18 as shown in FIG. 5 , and then flow into the axial groove G. At the communication portion of the circumferential groove 22 and the axial groove G, the groove depth of the axial groove G with reference to the second curved surface 18 is large as compared with the groove depth of the circumferential groove 22 . The foreign matters FM which flow into the axial groove G from the circumferential grooves 22 move to the groove bottom portion of the axial groove G, and follow the flow of the lubricant oil at a relatively high flow velocity in the circumferential oil groove 20 and are easily discharged to the outside of the bearing from the end surface portion in the bearing width direction ( FIG. 6 ). The foreign matters FM which move along the groove bottom portion of the axial groove G are hardly influenced by the dispersed flow of the lubricant oil flowing along the circumferential groove 22 to the side of the semi-cylindrical bearing 30 , and thus smoothly flow inside the axial groove G and are discharged to the outside of the bearing from the end surface portions in the bearing width direction.
As a result, according to the sliding bearing of the present embodiment using the semi-cylindrical bearing 10 having the second curved surfaces 18 , the influence of the foreign matters accompanying the lubricant oil can be reduced as compared with the conventional sliding bearing in which the foreign matters FM move only along the circumferential oil groove 20 , move to the sliding surface region of the semi-cylindrical bearing 30 by the momentum of the lubricant oil flow, and are concentrated and accumulated in the local portion of the region, and then are embedded in the sliding surface region.
The circumferential groove 22 communicates with the axial groove G in one of the slant surfaces 14 a which define the axial groove G. As for the groove depths of the circumferential groove 22 and the axial groove G in the communication portion, the depth of the circumferential groove 22 immediately before the intersection portion in which the both grooves intersect each other is compared with the depth of the axial groove G which is defined with reference to the virtual surfaces formed in the intersection portion by extending the second curved surfaces 18 and 38 of the semi-cylindrical bearings 10 and 30 .
Further, in FIG. 5 , a number of circumferential grooves 22 are illustrated only in the second curved surfaces 18 . However, a number of similar circumferential grooves directed in the circumferential direction, while they are not illustrated, also exist actually in the first curved surface 16 . | Disclosed is a sliding bearing for an internal combustion engine for supporting a crankshaft including a pair of semi-cylindrical bearings combined with each other into a cylindrical body. Each of inner circumferential surfaces of the respective semi-cylindrical bearings includes first and second curved surfaces following two kinds of arcs with different curvatures. The first curved surface is in a region including a circumferential central portion of the inner circumferential surface. The second curved surfaces are in remaining two regions of the inner circumferential surface. The circumferential oil groove and the axial groove communicate with each other. The circumferential grooves of the second curved surfaces and the axial groove communicate with each other. The groove bottoms of the circumferential grooves of the second curved surfaces are displaced to a side of the bearing inner circumferential surface from a groove bottom of the axial groove. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to dental implements. More specifically, it relates to a dental implement that uses pressurized medical grade nitrogen to impel granules of aluminum oxide entrained in the nitrogen flow for use in preparing a tooth for receiving a filling or composite restoration.
2. Description of the Prior Art
A new trend in dentistry is to replace the conventional, well known drill with a high velocity stream of gas having entrained particles within it. This allows for removal of the decayed area or old filling in or on the tooth's surface without heat or shock, and in many cases, without the use of anesthetics. Additionally, the surface is roughened during the process, which promotes better bonding with the composite material. One of the drawbacks of other intraoral air abrasive devices is their prohibitive cost. With the overhead burden on dentists already being extraordinarily high, this precludes many practitioners from obtaining them.
There have been a great many patents issued that relate to the present invention, and they will be discussed hereinafter, grouped according to the general thrust of their subject material.
The first group are the patents that deal specifically with entrained particles in a stream having a dental application.
In U.S. Pat. No. 3,626,841, issued on Dec. 14, 1971 to Zvi Harry Schachter there is disclosed an abrasive propellant apparatus. The mixing chamber of the device has a length of tubing having a threaded end. There is a cap having a flowable material inlet orifice at the base of the tube proximate the flexible conduit that connects the nozzle to the mixing chamber. This is an extraoral device that would be used for lab work. U.S. Pat. No. 4,941,298 issued on Jul. 17, 1990 to Mark Fernwood et al. discloses a rear reservoir micro sandblaster. In this invention, the body of the device has a pulverant material supply tube and a compressed air supply line. The compressed air supply tube is compressed by a pinch lever and, if this lever is depressed to allow the air to flow, a vacuum is created in the vortex chamber proximate the nozzle, which draws the pulverant material from the reservoir to the vortex chamber to mix with the gas, and thus be propelled out the nozzle. In contradistinction to the present invention, the Fernwood et al. device is primarily an extraoral device that, when used intraorally, is utilized for the repair of fixed prosthetics.
In U.S. Pat. Nos. 3,972,123 and 3,882,638 issued, respectively, on Aug. 3, 1976 and May 13, 1975, both to Robert B. Black there is disclosed air-abrasive prophylaxis equipment. Centrally disposed within the abrasive mixing device is a receptacle to receive the gasses, containing ports to mix the abrasive and the air as it is passed through. The abrasive laden gas is then directed through a controlling pinch valve to the hand piece.
Next is U.S. Pat. No. 4,174,571 issued on Nov. 20, 1979 to Ben J. Gallant. In this document, a method for cleaning teeth using water soluble abrasive particles is disclosed.
In U.S. Pat. No. 4,214,871 issued on Jul. 29, 1980 to Carter H. Arnold, there is disclosed a method and apparatus for cleaning teeth. The method disclosed involves water soluble halite pellets entrained within a liquid stream.
In U.S. Pat. No. 4,487,582 issued on Dec. 11, 1984 to George E. Warrin there is disclosed a dental cleaning system wherein a stream of soluble abrasive powder entrained in a stream of air is surrounded by a water spray curtain and directed at the surface of a tooth to clean the same.
The second group of patents are related to entrained abrasives in an air flow. These patents are listed below but will not be discussed in detail.
______________________________________PAT. NO. INVENTOR DATE OF ISSUE______________________________________3,163,963 Racine Caron January 5, 19653,618,263 Per Torsten Weijsenburg November 9, 19714,090,334 Benedict Kurowski May 23, 19784,708,534 Ben J. Gallant November 24, 19874,733,503 Ben J. Gallant et al. March 29, 19884,893,440 Ben J. Gallant et al. June 16, 1990DE 2314294 Robert B. Black October 18, 1973______________________________________
The next group of patents relate to tubal flow shutoff mechanisms. First is U.S. Pat. No. 3,759,483 issued to Thomas D. Baxter on Sep. 18, 1973. This control valve has a pair of ports that drive a piston connected to a cam member. When the piston travels, the attached camming member drives one of the two valve closure members towards the other, crimping the flexible conduit that lies between them.
Another tube flow shutoff device is seen in U.S. Pat. No. 4,635,897 issued on Jan. 13, 1987 to Ben J. Gallant. In this patent, a plunger cuts off the flow in the tube. The plunger is driven by a cylinder and piston arrangement that, in turn, is driven by compressed air or the like.
Another group of patents relevant to the present invention are those dealing with fiber optics associated with dental handpieces. First of these is U.S. Pat. No. 5,088,924 issued on Feb. 18, 1992 to Gary Woodward. This discloses a dental headpiece hose that with a plurality of inner components to provide drive air, an exhaust line, chip air, and coolant water. The hose also contains a fiber optic bundle for lighting the working area.
The other patent in this group is U.S. Pat. No. 5,096,418 issued on Mar. 17, 1992 to Ronald G. Coss. The device has a special channel within it to carry a fiber optic bundle for lighting the work area.
U.S. Pat. No. 3,067,765 issued on Dec. 11, 1962 to Robert H. Aymer et al. discloses a foot control for dental accessories.
And lastly, an American Dental Laser (ADL) brochure delineating the advantages of this type of device is enclosed. Unlike the present invention, the ADL device utilizes compressed air from the dentist's existing supply and further compresses this air to achieve a cutting level.
The present invention allows the practitioner to simply detach the standard air driven drill from the existing airflow control means and plug the air transport hose, with its conventional four hole connector, into the control unit of the instant invention for nitrogen flow control purposes. The present invention also allows for more inexpensive construction in that the pressures being generated at points along the gas flow and abrasive entraining route never exceed 170 PSI.
None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION
The present invention is a dental implement that uses a conventional tank of pressurized medical grade nitrogen, a flow control box downstream from it that receives input from a standard dentist's handpiece control, a fluid tight mixing chamber that holds the abrasive and includes a secondary nitrogen flow line that will create a fluid bed of N 2 and AlO 2 when sufficient gas flow is allowed to pass through it, thus entraining the AlO 2 abrasive within the nitrogen flow, and a handpiece that has a directing nozzle for application of the flow on a specific worksite with a fiber optic bundle including a replaceable light transmissive tip to direct light on the worksite. Although nitrogen is discussed in some of the prior art patents as being suitable for a propellant, in practice it is rarely used.
Accordingly, it is a principal object of the invention to provide a dental implement that can be used with the conventional air powered drill control means already present in the practitioner's office.
It is another object of the invention to provide a dental implement that can be easily attached to utilize the preexisting controls familiar to the operator.
It is a further object of the invention to provide a dental implement that utilizes medical grade nitrogen gas to entrain the abrasive particles, thus lessening the chance of harm in the case of an air embolism and obviating the possibility of contaminants being introduced into the abrasive stream.
Still another object of the invention is to provide a dental implement that uses a diverging valve to pass part of the moving gas into the mixing chamber to agitate the abrasive in a uniform manner consistent with differing gas pressures, thus allowing it to be entrained in the gas.
It is still yet another object of the invention to provide a dental implement that includes a fiber optic bundle with a resilient replaceable light transmissive tip protruding from the handpiece to assist in lighting the work area in the patient's mouth.
It is an object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of the present invention.
FIG. 2 is a side view of the internal components of the control box.
FIG. 3 is a perspective view of the mixing chamber.
FIG. 4 is a view of the handpiece and fiber optic bundle.
FIG. 5 is a cutaway view of the mixing chamber showing the travel of the flexible tube portion.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the present invention is shown. The line K that surrounds the components of the device indicates that in the preferred embodiment, the device in an enclosed single unit, preferably having wheels or the like (not shown). The first component consists of a nitrogen tank 10, containing medical grade nitrogen, that serves as a means to retain the nitrogen under pressure. Preferably, the tank is a size number 20 and includes a conventional regulator, such as a Williams #700 (not shown), to deliver the nitrogen at approximately 150 PSI. Of course other pressures could be chosen, depending on circumstances. Pressures ranging from 110 to 170 PSI are contemplated. Additionally, as is required by law, the gas line would include a safety relief valve 11. The nitrogen then flows through a containing and directing means in the form of a tube 12 that, by virtue of its construction, defines a downstream direction from the tank. The use of the medical grade nitrogen obviates the possibility of contaminants being introduced into the entraining gas stream.
The nitrogen enters the flow control means 100, best shown in FIG. 2. The control means allows the user to vary the volume of the gas flow upstream from the mixing chamber 200. The flow control means consists of an inlet port 102, a piston chamber 104, a piston 106, typically made of a Teflon material, an adjustable pinch bar biasing spring 109, and a rounded pinch bar 110 that adjustably crimps the tube 12 as it passes through the control means 100. Pinch bar 110 is pivotably attached to the control means 100 at a point 111 and the attachment is configured so as not to overstress the tube 12. The inlet port attaches by means of a conventional four hole connector to the existing air flow control means P that is present in almost all dental offices for attachment to a standard air drill. The airflow control means P delivers air from a compressor or the like (not shown). The user can typically control a flow of compressed air within a range of 0 to 40 PSI, flowing through the tube P1 into inlet port 102. The inlet port 102 has a threaded member 150 that is configured to receive the standard four hole connector on conventional hand piece hoses that are present in most dental offices. This controllable air flows fills the piston chamber 104 with air and forces piston 106 upwards, driving rounded pinch bar 110 upwards about pivot point 111 as shown by arrow 112 in FIG. 2, thus allowing the user to vary the volume of medical grade nitrogen gas allowed to pass through the control means 100 by means of the tube 12. Note that the piston 106 fits loosely into chamber 104 such that when air ceases to flow into the inlet port 102, the piston 106 will almost immediately be forced, by virtue of the pinch bar biasing spring 109, back to the bottom of the chamber 104 and the pinch bar 110 will close off the tube 12 by crimping the tube 12 against the shoulder 160. Additionally, the piston chamber has a vent 140 to enable the air to more quickly exit the chamber 104 once the controllable air flow stops. The vent 140 optionally could have an audible component that would allow the practitioner to determine the volume of nitrogen being passed by the control means. The chamber 104 further includes an air activated switch port Z that directs air entering the chamber 104 into a activation tube Z that leads to the fiber optic housing 302 (see FIG. 1) thus lighting the fiber optic bundle discussed hereinafter. Another feature of the control means 100 is the biasing spring adjustment means. The top wall 130 of the control means 100 has a bore 132 therethrough. This bore 132 is sufficiently large to pass the biasing spring 109 through it to contact the rounded pinch bar 110. Integral with the crimping shoulder 160 is a threaded member 162. The threaded member 162 passes through a pinch bar bore 132 and extends substantially above the top wall 130 of control means 100. The biasing spring 109 is placed on the threaded member 162 and then adjustment nut 164 is engaged with the threaded member 162 such that biasing spring 109 can be adjustably compressed in regards to the pinch bar 110.
Turning to the mixing chamber 200, shown in FIG. 3, it can be seen that it consists of a body portion 202 and top 204. Between the body portion 202 and top 204 is a double O-ring type seal 250 (see FIG. 5) held in place by bolts 252. These bolts are engaged by apertures (not shown) in both the body portion 202 and top 204 of the mixing chamber 200. The number of bolts employed could be as little as two or as many as would be necessary to secure the top 204. Additionally, the top 204 has a threaded fill cap 260 to allow the abrasive A to be replenished when necessary. Both the body portion 202 and top 204 are shown as transparent so that the internal details can be easily seen and the fill level of the abrasive monitored, but it should be understood that one or the other, or both of these pieces could be opaque if desired. Tube 12 carrying the nitrogen gas is split in a "Y" configuration at point 206 that defines a diverting valve. This valve could be either manually adjustable or could be pressure sensitive to the flow of nitrogen. A secondary tube 208 splits away from tube 12 and enters the top 204 of the mixing chamber 200. There are two one-way check valves V1 and V2 present to prevent any backflow from the mixing chamber 200. A rigid portion 210 extends into the mixing chamber 200 and is connected to a flexible end portion 212. Thus, when a sufficient volume of gas is allowed to pass the control unit 100, when it reaches the junction 206, part of the gas is diverted to the secondary tube 208. This then passes through the rigid portion 210 and the flexible portion 212. The flexible portion is free to move about an area, shown as the line X in FIG. 5. This allows for the aluminum oxide abrasive, designated A, to be evenly distributed within the gas stream. The abrasive is preferably about 50 microns in diameter, but different diameters, or mixtures of diameters, could be used. A range of 30 to 60 microns is contemplated. The flexible portion 212 could include a nozzle if necessary, depending on the size if the abrasive particles used. Additionally, under very low gas velocities, the aluminum oxide abrasive will not be agitated and thus the gas stream can be used to clean and/or dry the work area.
The invention includes a conventional dental light source (not shown) contained within a housing 302. A standard fiber optic bundle 304 transmits the light and projects it into the work area, as seen in FIG. 4. At the end of the fiber optic line is a light projecting tip 305. This tip is made of a semirigid plastic material and is press filled into the handpiece 400. As the light projecting tip becomes abraded by incidental abrasive flow, it can be easily removed and replaced. Preferably, the light is focused approximately 1-4 millimeters away from the end of the nozzle 404. In this type of dentistry, all tactile "feel" is removed, i.e. the pressure feedback from the enamel or decayed material being cut is not present. Thus, good lighting of the work area is critical, since the doctor is operating by visual cues alone. The handpiece 400 has a handle 402, that is adapted to fit easily in the user's hand. The nozzle 404 is made of a sufficiently hard material that it will not be easily worn by the entrained aluminum oxide and, preferably would be removably attached by threading or the like to the handle 402.
It is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims. | A dental implement is disclosed that uses a conventional tank of pressurized medical grade nitrogen, a flow control box downstream from it that receives input from a standard dentist's handpiece airflow control, a mixing chamber that holds the abrasive and includes a secondary nitrogen flow line that will "fluff up" the abrasive when sufficient gas flow is allowed to pass through it, thus entraining the abrasive within the nitrogen flow, and a handpiece that has a directing nozzle for application of the flow on a specific worksite with a fiber optic bundle having a replaceable, resilient light transmissive tip to direct light on the worksite. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates generally to washing machines and more particularly to a brake system for a washing machine or other appliance that can adapt to the size of the load held within the machine.
Vertical axis washing machines include a wash basket that spins about a vertical axis. Horizontal axis washing machines include a wash basket that spins about a horizontal axis. Other washer constructions have a tilted axis between vertical and horizontal. During a spin cycle following a rinse cycle, the wash basket spins at a fairly high rate of speed in order to extract water from the clothing that has been rinsed. Conventional vertical axis washing machines typically spin at a rate of about 600 to 650 revolutions per minute (RPM) or more.
Underwriters Laboratories (UL) require that, when a washing machine lid is opened during the spin portion of a cycle, the basket must stop spinning within 7 seconds. A brake mechanism is therefore required in order to slow down the rapidly spinning basket within this 7 second time interval. For conventional vertical axis washing machines, the brake mechanism typically applies the same braking pressure to the wash basket at any speed and for any wash basket load. This static or standard brake pressure has been satisfactory for the slower spin rate of these conventional machines.
However, new generations of washing machines are on the horizon that can spin the wash basket during a rinse cycle at much greater speeds, such as on the order of about 800 or greater RPM. The load required to slow and stop the wash basket within the 7 second interval is much greater at these higher rotational speeds. However, when a high braking load is applied to a wash basket that is spinning at this much higher rate and that contains a very light laundry load it produces undesirable consequences. For example, if a light load is held within the basket spinning at about 500 RPM, when the heavy brake load is applied, the washing machine components begin to vibrate and begin to cause significant noise, vibration and even movement or walking of the machine. At a minimum such conditions are unpleasant and could potentially cause more serious consequences.
Where a washing machine brake is incapable of meeting this 7 second requirement, a lid lock must be employed to prevent access to the wash drum until it has stopped spinning. Such a lid lock adds expense to the machine and creates a significant inconvenience to users.
SUMMARY OF THE INVENTION
In light of the above noted problems, it is an object of the present invention to provide a washer brake mechanism that applies sufficient brake torque for these relatively high RPM machines, but not the same brake torque under all washer conditions. It is another object of the present invention to provide a brake mechanism that does not produce a constant high brake torque that would be sufficient to brake a fully loaded basket of wet laundry and yet which would overpower a lightly loaded basket. It is a further object of the present invention to provide a washer brake mechanism that produces a variable brake torque sufficient for different laundry loads. It is yet another object of the present invention to provide a washer brake mechanism that applies a brake torque that is variable according to particular laundry basket conditions. It is another object of the present invention to provide a load adaptive washer brake mechanism that automatically adjusts the applied brake torque according to the mass of the load held within the wash basket and the rotational speed of the basket.
It is another object of the invention to provide a load adaptive brake system for an appliance in which a drive motor and the rotatable vessel are selectively coupled and uncoupled and a braking mechanism is selectively engaged and disengaged as the uncoupling and coupling occurs, respectively. It is a still further object of the invention to use the reactive force of the motor to disengage the braking mechanism if the rotating vessel is being slowed too quickly by the braking mechanism. A preferred embodiment of the invention is in a vertical axis washer, although the invention can also be used in horizontal and tilted axis washers as well as other appliances having a rotatable vessel.
These and other objects, features and advantages of the present invention are provided by a load adaptive brake system for an appliance according to the present invention. In one embodiment, the load adaptive brake system includes a stationary brake drum supported by the washing machine. The brake system also includes a brake plate and a pair of opposed brake shoes supported by the brake plate and including brake linings facing the brake drum. A spring is interposed between first ends of the brake shoes for forcing the brake pads against the brake drum. A cam is slidably carried on a rotary shaft of the washing machine and has a pair of cam surfaces. A roller is disposed on a second end of each of the brake shoes. Each roller bears against one of the cam surfaces of the cam. The cam surfaces each have a profile so that the cam will rotate to at least partly relieve brake pressure on the brake drum as the motor of the washing machine decelerates and applies residual deceleration torque through the motor armature to the cam if the motor is caused to decelerate faster than the normal uncoupled deceleration rate. That is, the motor has a normal deceleration rate when the motor is not coupled to the wash basket. This normal deceleration rate, in a preferred embodiment, is such that the motor would decelerate from full speed, at which the wash basket is rotating at least 500 rpm, and perhaps at 800 or greater rpm, to a stop condition in about 5½-6½ seconds.
The brake system was developed to be able to apply sufficient brake torque to stop a fully loaded wash basket from a full speed spin to a stopped condition in less than 7 seconds. When this same brake torque is applied to an empty wash basket, the basket is slowed from full speed to a stopped condition in about 2 seconds. While such a speed is well within the time requirements, such abrupt braking causes the entire washing machine to jerk and move about. If, however, the motor is coupled to the empty wash basket as the wash basket is being slowed down, the motor is caused to slow down faster than its normal deceleration speed, resulting in a reaction torque being developed by the motor and transmitted back to the cam, rotating the cam in a reverse direction to release the braking pressure of the brake pads against the brake drum. This causes a reduction in the net brake torque, thereby lengthening the time for the wash basket to come to a complete halt, would also prevent the machine from jerking and moving about. Since the motor naturally stops in less than 7 seconds, coupling the motor with the basket does not cause the coupled combination to stop in greater than 7 seconds because the reaction torque lessens as the stoppage rate approaches 5½ to 6½ seconds, and the lesser reaction torque becomes insufficient to overcome the strength of the spring through the cam, hence reapplying the brakes.
Thus, in a preferred embodiment, a mechanism is provided to automatically couple the basket to the motor if the basket is being slowed faster than the normal deceleration rate of the motor and to uncouple the motor from the basket if the basket is being slowed slower than the normal deceleration rate of the motor. The profile of the cam is selected such that the reaction torque enables the brakes to be at least partially released through rotation of the cam.
In another embodiment of the invention, a vertical axis washing machine includes a wash basket that is rotatable about a generally vertical axis. A rotary shaft is coupled to the wash basket and a motor is coupled to the rotary shaft for rotating the wash basket. A brake drum is stationary and supported by a portion of the washing machine. A brake plate supports a pair of brake shoes wherein the brake plate is carried by a portion of the rotary shaft of the washing machine and rotates relative thereto. A pair of brake shoes are supported by the brake plate wherein each brake shoe has a brake lining that can bear against the brake drum. A spring is interposed between first ends of the brake shoes that forces the brake linings against the brake drum. A cam is slidably carried on a portion of the rotary shaft and has a pair of cam surfaces. A pair of cam rollers are supported by respective second ends of the brake shoes. Each cam roller bears against a respective one of the cam surfaces of the cam. Each cam surface has a profile that is adapted to at least partly reduce the amount of brake pressure applied by the brake linings against the drum upon rapid deceleration of the motor through residual torques applied through the motor armature during rapid deceleration.
In another embodiment a load adaptive brake system is provided for an appliance which includes a motor, a drive wheel driven by the motor and a rotatable vessel. A brake surface is fixed relative to a non-movable portion of the appliance and at least one brake shoe carried by the vessel to rotate with the vessel. A biasing mechanism is engageable with the brake shoe to press the brake shoe into engagement with the brake surface. A cam is carried on the vessel, but is rotatable with respect thereto, and engageable with a portion of the brake shoe to overcome a bias of the biasing mechanism when the cam is rotated relative to the vessel in a first direction to disengage the brake shoe from the brake surface. A coupling mechanism is arranged between the drive wheel and the cam to selectively couple the motor to the vessel by rotation of the cam in the first direction when the drive wheel is rotating in one direction relative to the cam and to uncouple the motor from the basket when the drive wheel is rotating in a second, opposite direction relative to the cam.
These and other objects, features, and advantages of the present invention will become apparent upon a reading of the detailed description and a review of the accompanying drawings. Specific embodiments of the present invention are described herein. The present invention is not intended to be limited to only these embodiments. Changes and modifications can be made to the described embodiments and yet fall within the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view, partly in section, of a washing machine with a standard motor drive and showing the wash plate in an angled orientation.
FIG. 2 is a detailed sectional view of the washing machine of FIG. 1 and including a brake mechanism constructed in accordance with the present invention.
FIG. 3 is an enlarged view of the brake mechanism shown in FIG. 2 .
FIG. 4 is a cross section taken along line IV—IV of FIG. 3 illustrating the brake components.
FIG. 5 is a top elevational view of the cam driver and pawl of the washing machine of FIG. 1 .
FIG. 6 is a side elevational view of the pawl of FIG. 5 .
FIG. 7 is a top elevational view of the drive pulley of the washing machine of FIG. 1 .
FIG. 8 is a side sectional view of the drive pulley taken generally along the line VIII—VIII in FIG. 7 .
FIG. 9 is a top elevational view of the drive pulley and pawl where the drive pulley moves counter-clockwise relative to the output shaft.
FIG. 10 is a top elevational view of the drive pulley and pawl where the drive pulley moves clockwise relative to the output shaft.
FIG. 11 is a graph representing cam torque plotted against cam rotation.
FIG. 12 is a graph representing motor reaction torque back into the cam through the motor armature plotted against the brake time.
FIG. 13 is a graph representing various cam profiles wherein applied brake torque is plotted against brake time for various cam profiles.
FIG. 14 is a graph representing overall brake sensitivity to brake lining coefficient of friction with and without utilizing the cam effect of the present invention wherein brake torque is plotted against brake pad lining coefficient of friction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is particularly useful for a vertical axis washing machine of the type disclosed in FIGS. 1-2 and thus the preferred embodiment will be disclosed in this environment, although the invention is not so limited. In fact, the present invention can be utilized in other types of washers such as horizontal axis or tilted axis, as well as any other appliance which has a motor driven rotatable vessel. This could include dryers, centrifuges and other appliances.
A particular type of vertical axis washing machine is disclosed in U.S. Pat. No. 5,460,018, the disclosure of which is hereby incorporated by reference. The type of machine disclosed therein includes an agitator or wash plate that can operate vertically and also operate at an angle. The wash plate is driven by a drive system that together can operate at significantly higher rotational speeds such as on the order of 500 RPM or more. The present invention is directed to a brake mechanism and system for stopping rotation of the wash basket (rotating vessel) when a lid is opened during the spin cycle. The brake mechanism of the present invention is load adaptive and applies a varying brake torque, dependent upon the mass of the laundry load within the wash basket.
In FIGS. 1 and 2, reference numeral 20 indicates generally a washing machine of the automatic type, i.e., a machine having a pre-settable sequential controller 21 for operating the washer through a preselected program of automatic washing, rinsing and drying operations in which the present invention may be embodied. The controller 21 may be an electromechanical timer type device or an electronic microprocessor. The machine 20 includes a frame or cabinet 22 surrounding an imperforate tub 24 . A wash basket 26 with perforations or holes is rotatably supported within the tub and comprises a rotatable vessel into which a clothes load is placed. A fill valve 25 is connected to an external water supply (not shown) and is operated to inlet water into the tub. A hinged lid (not shown) is provided in the usual manner to provide access to the interior of the wash basket 26 .
The wash basket 26 defines a wash chamber and includes a generally cylindrical side wall 30 having a vertical center axis C—C. The side wall 30 includes a partly spherical wall portion 34 adjacent a substantially flat bottom wall 32 . A motor 40 is operatively connected to the basket 26 through a transmission 42 to rotate the basket 26 relative to the stationary tub 24 . A suspension frame 44 supports the motor and tub assembly within the cabinet 22 . The controller 21 is operatively interconnected with the motor and fill valve 25 such that the controller 21 can operate the washer 20 according to a selected program cycle.
The particular construction and operation of the agitation or clothes mover mechanism is not critical to the present invention, and could comprise one of many different constructions, such as those shown in FIGS. 1-2. The details of these constructions are known, for example as disclosed in U.S. Pat. Nos. 5,460,018 and 6,115,863 the full disclosures of which are incorporated herein by reference. Further details of the construction of those mechanisms is not included here, except to the extent necessary to describe the present invention.
A brake mechanism 64 embodying the principles of the present invention is shown environmentally in FIG. 3, and in greater detail in FIG. 4 .
FIG. 3 illustrates a detailed cross section of a portion of the wash basket 26 and drive system including the load adaptive brake system or brake assembly 64 according to the present invention. The motor 40 includes a downwardly depending motor shaft 100 that includes a drive pulley 102 thereon. A belt 104 is coupled to the pulley 102 and is rotated by the pulley and motor shaft. The drive pulley, of course, could be replaced with some other type of drive wheel, such as a gear, driven through a gear connection to the motor shaft 100 . The belt 104 is also wrapped around a larger diameter axial pulley 106 that is disposed adjacent the brake assembly 64 . The axial pulley 106 is affixed to an output shaft 62 and rotates in conjunction therewith. The top end of the output shaft includes a splined end that is coupled to a portion of a drive hub so that an agitator or wash plate 50 also rotates in concert with the output shaft 62 and the axial pulley 106 .
The brake assembly 64 is disposed adjacent the axial pulley 106 and concentric with the output shaft 62 and a spin tube 60 which is affixed to the wash basket 26 . The brake assembly 64 includes a brake drum 110 defining a depending annular wall 112 that is concentric with the shaft 62 and the spin tube 60 . The brake drum 110 is mounted fixed or stationary within the washing machine. In the present embodiment, the brake drum includes a central opening 114 that is fixed to a central stationary tube 116 that is also concentric with and houses the spin tube 60 and output shaft 62 .
The brake assembly 64 preferably also includes a pair of brake shoes 120 , 121 pivotally attached at a common pivot 122 to a stationary brake plate 124 (see also FIG. 4 ), although a single brake shoe could be utilized, or a number of brake shoes greater than two could also be utilized. The brake plate 124 and brake shoes 120 , 121 in the present embodiment are arranged generally horizontally relative the vertical axis of the machine. The brake plate 124 and the brake shoes 120 , 121 are carried by the wash basket 26 through a direct connection to the spin tube 60 which, in turn, is connected to rotate with the wash basket 26 . Hence, the brake plate 124 and brake shoes 120 , 121 rotate with the wash basket.
Each brake shoe 120 , 121 includes an arcuate vertical wall 126 that faces the annular wall 112 of the drum 110 when assembled. Each arcuate wall 126 has an exterior surface 128 with a friction enhancing brake lining 130 attached and sandwiched between the wall 126 and the annular wall 112 of the drum. Respective mid sections 132 of the brake shoes 120 and 121 are each attached at the pivot 122 to the brake plate 124 and can move relative to the pivot and one another. Each shoe 120 and 121 has a first end 134 that are opposed and biased away from one another by a biasing element or mechanism such as a coil spring or compression spring 136 . At rest, the spring 136 biases the first ends 134 away from one another forcing the brake lining 130 of each brake shoe into contact with the annular wall 112 of the brake drum 110 . A second end 138 of each brake shoe includes a low-friction roller 140 attached to each shoe. The roller 140 rides against a cam surface as described below. In one embodiment, each roller 140 is a ball bearing roller or track roller pressed in to a portion of each shoe with a roll pin. Such ball bearing rollers provide very low friction contact surfaces that are highly durable providing a highly consistent or constant coefficient of friction over their useful life.
Prior washing machine brake assemblies typically used a steel roller with a pin passing through the roller. Each pin was zinc coated to provided a low-friction surface contact between the pin and roller. The zinc coating would wear quickly producing a significant increase in coefficient of friction for the roller over the useful life of the roller. Such increase in the coefficient of friction creates a significant and undesirable change in brake performance.
The present invention also includes a cam assembly generally includes a cam 152 , a cam driver 154 , and a slip sleeve 156 . The cam 152 is received over the spin tube 60 and is free to rotate relative to the spin tube through an angle of less than 180°. A bushing 158 is received between the cam 152 and spin tube 60 and includes a flange 160 that extends between the cam and the brake plate 124 . The cam 152 bears against the flange 160 and thus against the brake plate 124 .
The cam 152 includes a pair of opposed cam surfaces 162 that have a particular gradual cam profile. The bearing rollers 140 on the second ends 138 of the brake shoes 120 and 121 bear against and ride along the cam surfaces 162 as described below. The cam 152 also includes a radial projection 164 that acts as a stop to limit travel of the bearing rollers 140 along the cam surfaces and to thus limit or control the amount of maximum brake pressure that is applied by the brake shoes against the drum 110 and to prevent further rotation of the cam 152 relative to the spin tube 60 .
The cam driver 154 is shown in FIG. 5 and is an annular ring that is also received along the spin tube 60 and can also rotate freely relative to the spin tube. The cam driver 154 includes a recess 166 that has a shape corresponding to that of the cam 152 . The cam driver 154 bears against a lower surface of the cam 152 and the cam seats within the recess 166 . The cam driver 154 therefore moves the cam 152 in conjunction with movement of the cam driver. The cam driver 154 includes a lever 168 that extends radially outward from the driver. A pawl 170 is pivotally attached to the lever 168 by a pin 171 and can move relative to the lever through a predetermined angular range. A pair of stops 172 (FIG. 6) project upward from the pawl and bear against the lever 168 in order to limit the angular travel of the pawl.
The axial pulley 106 is shown in sectional view in FIG. 8 and includes a recess 174 that faces the cam assembly 150 . The pawl 170 is substantially positioned within the recess 174 of the axial pulley. The recess 174 is defined by an annular outer wall 176 that faces the recess. The axial pulley 106 also includes a hub 178 that also faces the cam assembly 150 . The hub 178 has an upper face that includes a bearing 180 that rides against a bottom surface 182 of the cam driver 154 . The axial pulley 106 and vertical shaft 62 rotate as one, and the bearing 180 provides a low-friction contact surface between the hub 178 and the spin tube 60 .
As shown in FIG. 8, the slip sleeve 156 is received around the hub 178 and is free to rotate around the hub. The slip sleeve 156 includes a lifter 184 extending radially outward from the sleeve. As illustrated in FIGS. 9 and 10, depending upon the rotation direction of the axial pulley 106 relative to the output shaft 62 , both the slip sleeve 156 and lifter 184 will come in contact with one end or the other of the pawl 170 causing the pawl to rock or pivot around the pin 171 in one direction or the other until one of the stops 172 contacts the lever 168 of the driver 154 .
During the spin mode, the motor 40 drives the drive pulley 106 which moves counter-clockwise relative to the initially stationary basket 26 and connected spin tube 60 . Thus, the drive pulley 106 moves counter-clockwise relative to the cam driver 154 which is carried on the spin tube 60 . This situation is illustrated in FIG. 10 .
As shown in FIG. 10, when the axial pulley 106 rotates in a relative clockwise direction, as indicated by arrow 187 , as compared to the pawl 170 which is carried by the cam driver, the lifter 184 will engage near a second end 170 b of the pawl 170 , causing the second end 170 b to move outwardly and a first end 170 a to move inwardly. This coupling mechanism causes a driving connection to occur between the motor 40 and the basket 26 , and hence the motor and basket are coupled and the basket is caused to rotate at a speed determined by the speed of the motor.
When the drive pulley 106 rotates in a relative clockwise direction, as indicated by arrow 187 in FIG. 10, as compared to the pawl 170 which is caused by the cam driver, the lifter 184 will engage near the second end 170 b of the pawl 170 , causing the second end 170 b to move outwardly and the first end 170 a to move inwardly. A key or catch 186 is carried on the annular wall 176 within the recess 174 of the drive pulley 106 . The catch 186 comprises a notch that corresponds in shape to the second end 170 b of the pawl 170 . The catch 186 catches the pawl 170 as described below which rotationally locks up the axial pulley 106 with the cam assembly 150 also as described below.
The torque of the motor 40 , acting through the pawl 170 on the cam driver 154 causes the cam driver, and hence the cam 152 , to rotate, causing the rollers 140 to ride on the cam towards a thicker profile, thus acting against the spring 136 and releasing the brake shoes 120 , 121 from the annular wall 112 of the brake drum 110 . When this occurs, and the rollers reach the end of their travel, the entire brake assembly, except the stationary brake drum 110 , will begin to rotate, and hence the spin tube 60 , to which the brake plate 124 and wash basket 26 are secured, will rotate.
When power to the motor 40 is terminated, the motor will begin to decelerate at a predetermined rate. This will cause the drive torque to no longer be applied through the drive pulley 106 and pawl 170 to the cam driver 154 , hence allowing the power of the spring 136 to cause the rollers 140 to begin to move toward a thinner portion of the cam profile, and allowing the brake shoes 120 , 121 to engage the brake drum 110 .
If the wash basket 26 is heavily loaded, it will slow down more slowly than the motor 40 , and the drive pulley 106 , connected to the motor 40 , will rotate counter-clockwise (as in FIG. 9) with respect to the spin tube which carries the cam driver 154 and pawl 170 . As this happens, the lifter 184 will engage the first end 170 a of the pawl 170 and will release the second end 170 b from the catch 186 . The motor 40 and wash basket 26 will then be uncoupled and will stop at their own rates.
If the wash basket 26 is lightly loaded, it will slow down more quickly than the motor. This will cause the drive pulley 106 to rotate clockwise with respect to the cam driver 154 and pawl 170 (FIG. 10 ). As this happens, the lifter 184 will engage the second end 170 b of the pawl 170 and cause it to engage the catch 186 , thereby coupling the motor and the wash basket. Since the brake, in this scenario, is causing the basket to slow more quickly than the motor, the motor will generate a reactive torque, which will be transmitted through the cam driver 154 to rotate the cam 152 and to release the brake, thereby reducing the brake torque and lengthening the time required to bring the wash basket to a complete stop.
Thus, in a heavily loaded basket condition, the motor and basket will be automatically uncoupled and the brake will be able to apply full braking torque on the basket to slow it down. On the other hand, in a lightly loaded basket condition, the motor and basket will be automatically coupled and the reaction torque of the motor will operate through the rotation of the cam to reduce the braking torque, thereby preventing jerking and movement of a lightly loaded washer. In this manner, the braking system automatically adapts to the mass of the load in the basket and effectively adjusts the braking torque in response to the size or mass of the load.
When viewed from above, as in FIG. 10, the drive pulley 106 rotates in a clockwise direction when the cam assembly locks up with the drive pulley and in a counter-clockwise direction, as in FIG. 10, when the drive pulley and vertical shaft 62 rotate independently of the spin tube, brake assembly and cam assembly components. When the drive system including the drive pulley 106 is rotated in a clockwise direction, the machine is operating in the spin cycle. The drive belt and pulley are rotated at a high RPM, such as for example, 500-800 RPM. The pawl 170 of the cam driver 154 is lifted by the lifter 184 of the slip sleeve 156 . The second end 170 b of the pawl 170 is received in the catch 186 to lock up the drive pulley 106 and the cam assembly 150 . Torque provided by the motor is transmitted to the drive pulley 106 . Since the cam assembly 150 is locked up with the drive pulley, the cam rollers 140 ride up or along the cam surfaces 162 which thus compresses the biasing element or spring 136 . The brake shoe linings 130 are moved away from the brake drum 110 releasing the brake and permitting the wash basket to rotate freely at the high rate of speed. The amount of torque applied through the drive pulley determines how far up the cam surfaces that the cam rollers 140 move. The more torque applied by the motor, the further the cam 152 rotates and hence the further the cam rollers 140 move along the cam surfaces 162 . The cam surfaces 162 are of a very low profile and therefore it will take longer than in previous constructions for the roller bearings 140 to ramp down when the motor torque is removed.
The compression force of the spring 136 and the profile geometry of the cam surfaces 162 determine the variability of the brake mechanism 64 of the present invention. A lightly loaded wash basket requires little motor torque applied in order to spin the basket at a high rate of speed. Much additional torque must be input by the motor to spin a heavily loaded basket. The low cam profile of the invention permits the cam to operate and release the brake at much lower motor input torques, and on the order of about 30% of the motor torque than was previously required to operate or release the brake mechanism.
FIG. 11 illustrates a graph wherein cam torque is plotted against cam rotation in degrees. As can be seen, the brake mechanism releases the brake with only about 0.85 newton meters (Nm) of torque. When the brake cam operates at such low torque values, the brake cam can be actuated by the reaction torque of the motor armature when the motor decelerates from maximum spin speed to a stopped condition.
FIG. 12 illustrates a graphic representation of motor representation of motor reaction torque input back into the brake cam through the motor armature against measured braking time. Motor reaction torque back into the brake cam dissipates over time. With prior art brake mechanism designs, motor reaction torque had little or no effect on brake pressure because a minimum of 2.5 newton meters of drive torque was required to release the brake. Thus, full brake pressure would be applied virtually from the instant the motor drive energy was stopped. In contrast, with the present invention, motor reaction torque is sufficient to act against the brake cam in order to partly relieve brake pressure. The graph shown in FIG. 12 illustrates the torque required to decelerate the motor armature as a function of the brake time. The longer the brake time, the lower the motor reaction torque. When a wash basket is fully loaded, the brake time will be long and in contrast, when the wash basket is lightly loaded the brake time will be short. For long brake times, the amount of motor reaction torque that is fed back into the brake cam is low enough that the motor reaction torque will not relieve or reduce braking pressure. Thus, full brake pressure is applied by the brake of the present invention. For a lightly loaded wash basket, the brake time is significantly shorter. When the brake time approaches 2.5 seconds or less, the motor reaction torque as can be seen in FIG. 12 becomes large enough to partly or completely balance against the brake spring force to at least partly disengage the brake and thus reduce braking pressure. This will extend the braking time. This phenomena produces an adaptable brake mechanism. When the wash basket is lightly loaded, the brake will therefore not fully apply and will prevent vibration, movement of the machine, and possible damage to the components.
FIG. 13 is a graphic representation of various cam profiles wherein brake torque is plotted against brake time. The upper curve shows brake torque that is applied by the braking mechanism versus braking time wherein no cam effect was utilized. The lower curve illustrates a brake cam of the present invention having a very low cam profile. The intermediate curves show cams having higher cam profiles. As can be seen upon a review of FIG. 13, applied brake torque is significantly reduced for short braking periods which represent light wash basket loads. This is the primary desired effect of the invention. The upper curve represents a brake mechanism with no cam effect and illustrates that the brake torque is very high for short braking times. This system with no cam effect would produce undesirable results such as system vibration and movement of the washing machine.
FIG. 14 is a graphic representation of overall braking sensitivity plotted against brake lining coefficient of friction. FIG. 14 includes two separate data groups, one representing a brake mechanism including the cam effect of the invention and a brake mechanism without the cam effect. Brake torque is actually plotted against brake lining coefficient of friction. As can be seen upon review of this figure, the effect of differences in brake lining coefficient of friction is reduced when a brake mechanism including the cam effect of the present invention is utilized. The upper graph illustrates a greater range of brake torque applied by the brake mechanism and represents a brake mechanism with no cam effect. A reduced differential brake torque is provided when a brake cam of the present invention is utilized for different brake linings.
The present invention is for a brake mechanism that includes a cam that releases and applies the brakes of the mechanism depending upon rotation of the cam. The cam is in turn rotated by applied motor torque. When the motor torque is released, residual deceleration torque from the motor armature has an effect on the return rotation of the cam. Residual motor torque is applied at the early stages of motor deceleration greater than at the latter stages. Therefore, when a light load of laundry is carried within the wash basket of the washing machine, the braking time is relatively short. However, because the residual motor torque acts to at least partly reduce the amount of braking pressure, the braking time is increased and the brake pressure is reduced at the beginning of the brake cycle. For heavier loads of laundry, the motor deceleration torque has little no effect on brake pressure.
The present invention has been described utilizing particular embodiments. As will be evident to those skilled in the art, changes and modifications may be made to the disclosed embodiments and yet fall within the scope of the present invention. The disclosed embodiments are provided only to illustrate aspects of the present invention and not in any way to limit the scope and coverage of the invention. The scope of the invention is therefore only to be limited by the appended claims. | A load adaptive brake system is provided for an appliance which includes a motor, a drive wheel driven by the motor and a rotatable vessel. A brake surface is fixed relative to a non-movable portion of the appliance and at least one brake shoe carried by the vessel to rotate with the vessel. A biasing mechanism is engageable with the brake shoe to press the brake shoe into engagement with the brake surface. A cam is carried on the vessel, but is rotatable with respect thereto, and engageable with a portion of the brake shoe to overcome a bias of the biasing mechanism when the cam is rotated relative to the vessel in a first direction to disengage the brake shoe from the brake surface. A coupling mechanism is arranged between the drive wheel and the cam to selectively couple the motor to the vessel by rotation of the cam in the first direction when the drive wheel is rotating in one direction relative to the cam and to uncouple the motor from the basket when the drive wheel is rotating in a second, opposite direction relative to the cam. | 3 |
FIELD OF THE INVENTION
The present invention relates to a process for extraction of myelin basic protein from myelin containing tissue, such as central nervous system tissue, which process produces highly purified myelin basic protein in a short time. The protein product recovered includes, in addition to the major myelin basic protein isoforms, also several minor isoforms not generally obtained by other methods (Mastronardi, F. G. et al., J. Neurochem. (1993) 60, 153-160).
BACKGROUND OF THE INVENTION
Myelin is a unique multilamellar membrane structure that surrounds and electrically insulates axons to facilitate the conduction of neuronal impulses. This elaborate structure is synthesized and assembled by oligodendrocytes in the central nervous system (CNS) and by Schwann cells in the peripheral nervous system (PNS) (de Ferra, F. et al., Cell 43, Part 2, (1985) 721-727; Nakajima, K. et al., J. Neurochemistry, 60 (1993) 1554-1563). Myelin basic protein (MBP) is one of the major constituents of the central nervous system myelin, since it constitutes approximately 30% of its myelin proteins.
Mouse MBP is known to have at least four isoforms as translated proteins (Barbarese, E. et al., Proc Natl. Acad. Sci. USA, 74 (1977) 3360-3364). The molecular weight of these proteins are 21.5, 18.5, 17 and 14 kDa. Recently separate mRNAs for 21.5, 20.2, 18.5, 17 (two isoforms), one isoform between 17 an 14 kDa and under 14 kDa have been reported (see FIG. 3 in reference Nakajima, K. et al., ibid.).
Experimental allergic encephalomyelitis (EAE) is a widely used animal model for multiple sclerosis (MS), where MBP is considered one putative autoantigen. EAE can be induced in rodents by immunizing the animals with MBP in strong adjuvant. On the other hand, oral administration of pure MBP is shown to tolerize animals for MBP inhibiting EAE induction (Miller, A. et al., FASEB, 5 (1991) 2569-2566; Miller, A. et al., Pros Natl. Acad. Sci USA, 89 (1992) 421-425). In the USA, trials are ongoing where bovine MBP is orally administered to MS patients (Weiner and Hafler, unpublished). Further, MBP may be involved in the pathogenesis of other neurological disorders (Carnegie P. R. and Moore, Proteins of the Nervous System, Raven Press (1980) 2nd ed. pp. 119-143).
Several methods for the purification of MBP have been established. Most of them are based on primary extraction of lipids from the brain tissue with subsequent separation of major myelin basic protein isoform or isoforms from other components soluble in aqueous buffers (Deibler G. E. et al., Prep. Biochem., 2 (1971) 139-165; Eylar E. H. et al., Methods Enzymol., 32 (1974) 323-341; Bellini, T. et al., J. Neurochemistry, 46 (1986) 1644-1646; Giegerich, G. et al., J. Chromatogr., 528 (1990) 79-90). Also extraction using detergents has been reported (Riccio, P. et al., Mol. Chem. Neuropathol., 13 (1990) 185-194). Detergents, in general, inhibit immunological assays. Common to all the methods is that they include multiple steps of extraction of lipids followed by separations of the remaining proteins using different chromatographic steps. These are time consuming and hence expose MBP to proteolytic degradation, which is known to be active in central nervous system tissue due to high activities of neutral and acidic proteases.
Most widely used processes (Eylar, E. H. et al., ibid.; Deibler, G. E. et al., ibid.) start with the extraction of MBP containing tissue with a chloroform-methanol mixture, which renders MBP water soluble. Hence the MBP is among a variety of other CNS proteins, from which it has to be separated.
In one known purification process, MBP was purified from insoluble material from chloroform-methanol and acetone treated CNS tissue or sucrose gradient isolated myelin from rat brain or spinal cord. The remnants from solvent treatments or purified myelin were washed with pH 3.0 water, and MBP was extracted from the debris with 0.1M HCl (Martenson, R. E., J. Biol. Chem., 244(16) (1969) 4268-4272). That study confirmed earlier observations that rat MBP consists of multiple electrophoretic forms.
In another known purification procedure of MBP, extracts of canine and porcine brain were treated in a sequential manner with chloroform-methanol (2:1 v/v), acetone, and deionised water (Pitts, O. M. et al., Prep. Biochem. (USA), 06(04) (1976) 239-164). This was followed by a precipitation of the extract at pH 9.0, and gel filtration of the supernatant in dilute hydrochloric acid.
None of these processes mentioned above results in the simultaneous purification of different MBP isoforms in the brain, as does the process of the present invention. Some of these isoforms are implicated as potential autoantigens in multiple sclerosis (MS) (Voskuhl, R. R. et al., J. Neuroimmunology, 42 (1993) 187-192; Voskuhl, R. R. et al., J. Immunology, 153 (1994) 4834-4844).
According to the present invention a simple extraction procedure has been developed which produces highly purified MBP in a short time. The protein product according to the process includes, in addition to the major MBP isoforms, also several minor isoformic myelin basic proteins not generally obtained by prior processes. Moreover, isoforms only predicted on the basis of presence of mRNA in the central nervous system tissue (Nakajima, K. et al., J. Neurochemistry, 60 (1993) 1554-1563) can be detected in the myelin basic protein prepared according to our invention when analysed with specific antiserum.
SUMMARY OF THE INVENTION
The object of the present invention is thus a process for extraction of myelin basic protein from myelin containing tissue, such as central nervous system tissue, which process comprises the following steps:
extraction of the myelin basic protein from the myelin containing tissue with an organic solvent selected from the group consisting of chloroform and compounds having a polarity similar to that of chloroform;
incubation of the organic phase in the presence of a lower aliphatic alcohol or propylene glycol;
transfer of the myelin basic protein from the organic phase into an aqueous phase with the aid of hydrogen ions (protons); and
recovery of the purified myelin basic proteins.
REFERENCE TO THE DRAWING
In the appended figures, the coomassie stainings were made to 0.75 mm thick SDS-PAGE minigel when 4 μg proteins according to Bradford analysis is used as a sample. Similar gels were run for immunoblot analysis. Proteins were electro-transferred onto nitrocellulose filters. Polyclonal anti guinea-pig MBP serum raised in rabbit by guinea-pig MBP purified by the method of Eylar et al. (1971, ibid.) was used as primary antibody. Horseradish peroxidase-conjugated goat anti rabbit IgG conjugate was used as secondary antibody. Immunoreactions were visualized by enhanced chemiluminescence (Amersham).
FIG. 1 shows at A) coomassie staining of the final myelin basic protein product from various species and at B) and C) immunoblot of similar gel (15 second and 40 second exposures during enhanced chemiluminescence, respectively). Lane 1, Promega low molecular weight marker; lane 2, bovine MBP; lane 3, human MBP; lane 4, porcine MBP; lane 5, rabbit MBP; lane 6, chicken MBP; lane 7, guinea-pig MBP; lane 8, rat MBP; lane 9, mouse MBP; lane 10, fish (Lota lota) MBP.
FIG. 2: MBP isoforms visualized with coomassie staining (A) or immunoblot detected with enhanced chemiluminescence (B). Lane st, Promega medium range, molecular weight marker; lane 1, mouse brain homogenate (500 μg); lane 2, MBP from mouse brain (8 μg); lane 3, spinal cord homogenate (500 μg); lane 4, MBP from mouse spinal cord (5 μg). The exonic elements in mRNAs corresponding to the distinct isoforms are drawn according to Nakajima et al. (1993). Note that the relative mobility of MBPs is reduced compared to standard proteins of similar size.
In FIG. 3 matrix-assisted laser desorption mass spectrometry (LASERMAT) results for A) mouse and B) human MBP is presented. The analysis was performed in a Finnigan-MAT apparatus using 100 pmol protein sample mixed into sinapinic acid. For human MBP, the m+2H + peak (9.3 kDa) is also visible.
FIG. 4 shows peptide-grade SDS-PAGE analysis of the product. The analysis was performed for human and mouse MBP by a Pharmacia Phast System machine. A: coomassie staining, B: immunoblot analysis. Lane 1, human MBP; lane 2, mouse MBP; lane 3, guinea-pig MBP digested partially by thrombin. The two major bands in the thrombin digest have molecular weights of 10.5 kDa and 8 kDa. Using 3 min illumination in chemiluminescence reaction detection (Amersham), no stainable or immunoreactive low molecular weight degradation products can be observed.
FIG. 5. Effect of the wash of the organic phase with neutral water. A: coomassie staining, B: immunoblot analysis. Lane 1, wash water phase; lane 2, final product when organic phase was washed with neutral water; lane 3, final product without wash. The washed proteins constitute about 2-5% of the proteins in the organic phase.
FIG. 6: Stability of the product. Lane 1, frozen lyophilized product; lane 2, product kept one week in water solution at room temperature; lane 3, product kept one week at +4° C. All MBP samples were made from porcine brain.
FIG. 7. MBP products made from mouse brain kept at +4° C. post mortem. Lane 1, fresh brain; lane 2, 4 h incubation; lane 3, 1 day incubation; lane 4, 4 days incubation; lane 5, 8 days incubation.
DETAILED DESCRIPTION OF THE INVENTION
The process according to the invention is based on the extraction of myelin containing tissue such as brain tissue with an excess of organic solvent. Thus the myelin basic protein isoforms are almost exclusively transferred into the organic solvent.
By the term "myelin containing tissue" is meant such as that of the central nervous system and the peripheral nervous system. The tissue can be fresh or frozen.
The term "organic solvent" means in this context an organic solvent having a polarity similar to that of chloroform (E 2 Al 2 0 3 =0.38 -0.42), such as chloroform, methylene chloride and diethylether.
The ratio of organic solvent to tissue is not critical, but a preferred range is 3 to 8 ml organic solvent per 1 g myelin containing tissue. In a preferred embodiment, chloroform is used in ratio of a total of 7.5 ml solvent--in 5 ml and 2.5 ml batches--per 1 g myelin containing tissue.
This means that pro each mg of pure myelin basic protein about 1.5 ml (spinal cord) to 5 ml (frozen brain) organic solvent is used. Preliminary analysis show that the organic solvent can be recycled, i.e. the organic solvent fraction, which has already been used to extract myelin basic proteins, can be used to extract more of it from another sample of myelin containing tissue. After extraction, the organic phase is preferably washed with neutral water in order to remove proteins soluble at neutral pH. Such proteins constitute generally about 2 to 5% of the proteins carried in the organic phase.
In the next step of the process the myelin basic protein isoforms extracted into the organic solvent are made water soluble. This is done using a lower aliphatic alcohol or propylene glycol and hydrogen ions. The organic phase is incubated at room temperature in the presence of a lower aliphatic alcohol or propylene glycol. The preferred range of lower aliphatic alcohol or propylene glycol is 1 ml per 2 ml organic solvent containing myelin basic protein. This step is essential to render the myelin basic protein in the organic phase transferrable to the aqueous phase.
In this context, by the term "lower aliphatic alcohol" is meant the following alcohols:
______________________________________ alcohol yield______________________________________ methanol +++ ethanol +++ propanol +++ 2-propanol +++ butanol ++ 2-butanol ++ iso-amyl alcohol + tert-amyl alcohol ++______________________________________
In addition, the yield by propylene glycol is comparable to that obtained by methanol.
After incubation with lower aliphatic alcohol/propylene glycol, the myelin basic protein isoforms are quantitatively transferred from the mixture of organic solvent and lower aliphatic alcohol/propylene glycol into acidic water, which is preferably used in a ratio of 1 ml water per 6 ml of mixture of organic solvent and lower aliphatic alcohol/propylene glycol. Hydrogen ions (protons) are used to carry myelin basic proteins into the aqueous phase by acidifying the aqueous phase with for example hydrochloric acid. As long as the organic solvent containing myelin basic protein has buffering capacity so that the pH of the acidified aqueous phase rises when mixed with the mixture of organic solvent and lower aliphatic alcohol/propylene glycol, more myelin basic protein can be transferred from the mixture of organic solvent and lower aliphatic alcohol/propylene glycol into the aqueous phase. The pH is kept preferrably at about 2. From the aqueos phase thus obtained the myelin basic proteins are recovered. This can take place, for example, by freeze-drying the product twice or gel filtration and freeze-drying. According to a preferred embodiment, the product is gel filtrated and freeze dried.
During the purification process of the present invention myelin basic protein most probably locates itself immediately into the organic phase. This results in that the degree of possible proteolysis of the myelin basic protein is minimized.
Although it is still unknown if the myelin basic protein is present in the organic solvent in soluble form, or in the form of lipid-associated micelles, we have indicated by thin layer chromatography that the myelin basic protein is lipid-bound in the lyophilized preparate. The nature of this (these) lipid(s) is not known.
The invention will now be described in more detail below by means of an example.
EXAMPLE
Preparation of the myelin basic protein product
3.08 g frozen mouse brain was homogenized into 15 ml of chloroform at room temperature (RT) with a Sorvall Omni-Mixer 17220 homogenizer using four 30 second bursts at full speed intervened by 30 second pauses to avoid excess heating. The organic phase was separated from tissue debris and intracellular/cytosolic fluid by centrifugating 5 min 4500 rcf at RT with a Sorvall SA-600 rotor. The intracellular/cytosolic fluid was discarded and the debris was re-extracted with 7.5 ml chloroform using two bursts in the homogenizer and the organic phase was separated as before. The chloroform fractions were pooled and the volume was measured to be 18.2 ml.
The organic phase was washed in a 50 ml conical tube by adding 4.5 ml neutral water and vortexing gently for 15 seconds. The water phase was separated by centrifugating 5 minutes 2000 rpm with a Sorvall H5094 rotor at RT. The water phase was carefully removed from the top of the organic phase.
To the chloroform phase 9 ml methanol was added and the mixture was vortexed for 30 seconds. Then, 4.5 ml water and 120 μl 1M HCl was added. The mixture was vortexed and the pH of the separating aqueous phase was checked periodically by Acilit (Merck) pH paper. As long as the pH arose during vortexing, more 1M HCl was added. After adding 140 μl 1M HCl, the pH of the aqueous phase remained 1.5-2.0.
The acid aqueous phase was separated from the organic phase by centrifugating 10 min at 2000 rpm with a Sorvall H5094 rotor at RT. Total 9 ml of acid aqueous phase was recovered, concentratred to 3 ml in a Buchi Rotavapor vacuum concentrator, gel filtrated in a Pharmacia PD-10 column and lyophilized. The final product appeared as a white powder and the total yield of protein was 4.3 mg according to Bradford analysis.
Analysis of the myelin basic proteins obtained by the method
Using 4 μg protein samples from various species all proteins visible in the coomassie stained 0.75 mm thick SDS-PAGE react with the polyclonal myelin basic protein specific antiserum. The serum was raised in rabbits by immunizing with guinea-pig myelin basic protein purified by the method of Eylar et al. (1974).
Immunoreactive bands corresponding to nearly all isoforms predicted for mouse by mRNA analysis, but not analyzed for other species could be detected in all mammalian myelin basic protein samples tested (See FIG. 1A, B and C and Table 1). Moreover, immunoreactive bands are also detected, which are not visible in coomassie staining but the size of which agrees with the predicted myelin basic protein isoform size determined by mRNA analysis (See FIG. 1 and Table 1).
All MBP isoforms detected in brain and spinal cord homogenates were also present in the final product (FIG. 2).
Purity and solubility of the product
The final myelin basic protein preparation is readily soluble in aqueous solvents such as distilled water and phosphate buffered saline (PBS). After two lyophilisations or gel filtration and lyophilisation, the protein appears as a white powder. No contaminating proteins were detected by coomassie staining, reversed-phase high-performance liquid-chromatography (RP-HPLC) or immunoblot analysis. Molecular weight analysis by matrix-assisted laser-desorption mass spectrometry (LASERMAT) of the myelin basic protein preparations from human and mouse showed that at least the molecular weights of the major isoforms (only the weights of the major isoforms were measureable by LASERMAT) corresponded to those predicted from mRNA, confirming that at least those isoforms are nondegraded (See FIG. 3). Peptide grade SDS-PAGE analysis by Pharmacia Phast System revealed no bands below approximately 10 kDa, further supporting that the protein products are intact (See FIG. 4). Also a partial thrombin digestion (Law, M. J., et al., J. Neurochem.,42 (1984) 559-568) of the myelin basic protein preparation results in the typical peptide pattern.
The importance of neutral water wash to the organic phase is not clear as no difference in the protein content of the final product could be demonstrated, whether the organic phase is washed or not. However minor amounts of proteins nonrelated to myelin basic proteins could be seen in the water phase used to wash the organic phase (See FIG. 5).
Yield
One gram fresh brain yields about 1.5 (frozen brain) to 5 milligrams (spinal cord) a highly purified myelin basic protein isoform mixture. The yield is in same range as obtained by other published methods (see Table 2).
The extraction of myelin basic protein seems to function equally with all species tested (see FIG. 1 and Table 1), and both brain and spinal cord tissue (FIG. 2) are suitable raw materials for purification of myelin basic protein from the central nervous system. The method is also suitable for purification of myelin basic protein from the peripheral nervous system.
Isoforms
The best characterized species for myelin basic protein mRNA expression is mouse. Detected messenger RNAs of mouse myelin basic protein encode 13.0, 14.2, 16.0, 17 (two isoforms) ,18.5, 20.2, and 21.5 kDa polypeptides (deFerra, F. et al., 1985, ibid.; Nakajima, K. et al.,1993, ibid.). A protein corresponding to the 21.5 kDa and 16 kDa myelin basic protein isoforms are present in preparations from each species except fish. For human the 21.5 kDa isoform, now detected in the purified preparate by immunoreaction (FIG. 1C, lane 3), has only been predicted by mRNA analysis from myelinating and remyelinating brain tissue (Kamholz, J. et al., (1986) Proc. Natl. Acad. Sci. USA 83, 4962-4966). The 16 kDa isoform present also in human myelin basic protein preparate has not--according to the literature--been predicted for human by mRNA analysis. These isoforms contain an amino acid sequence encoded by exon-2 of the myelin basic protein gene. This region of MBP has shown to be recognized by myelin basic protein specific T cell lines from MS patients (Voskuhl, R. R. et al., (1993), ibid.), thus possibly being of key importance when myelin basic protein tolerisation treatments are planned for MS patients. These exon-2 containing isoforms were present in substantial amounts in porcine and bovine myelin basic protein preparates--species suitable as a source of large scale myelin basic protein purification.
The 14.2 kDa band representing the major polypeptide for mouse MBP and rat MBP was present also in all other species. Messenger RNA encoding for an approximately 13 kDa isoform was recently detected for mMBP (Mathisen, P. M., et al. (1993) Proc. Natl. Aca. Sci. USA 90, 10125-10129). A protein of corresponding size was recognized by the MBP-specific antiserum in extracted mouse and rat samples and weakly also in other mammalian species after prolonged exposure (FIG. 1C). Additionally in rMBP and mMBP an approximately 10 kDa polypeptide became visible in immunoreaction (FIG. 1C, lanes 8, 9).
Stability
The myelin basic protein preparate is stable as a powder at -20° C. for at least two years. In aqueous solution, after storage for one week at room temperature or at +4° C., no degradation was observed with coomassie staining or immunodetection (FIG. 6). The stability may result from high selectivity on transfer of myelin basic proteins into the organic phase and further into the aqueous phase and the denaturing effect of chloroform and acid pH for proteases.
We found out that myelin basic proteins can still be extracted in substantial quantities from brain stored for one week at +4° C. (see FIG. 7). Hence, no expensive deep freeze chain is needed for raw material handling and transport. Once the tissue has been frozen and thawed, the myelin protein yields are markedly lowered.
Time considerations and scalability
In laboratory scale, meaning in this context purification of myelin basic protein from 100 mg to 100 g CNS tissue, the time required from beginning of the purification from tissue to a preparate ready for lyophilisation is approximately three hours. This is remarkably faster compared to the one day when using the shortest published method (Bellini et al., ibid.) and to 5 days by the commonly used methods of Deibler G. E. et al., (1971) and Eylar E. H. et al., (1974).
So far the method has been shown to function for small tissue samples of 100 mg to preparative laboratory scale using 100 g of tissue as a starting material. No reason to inhibit scaling the method for large industrial scale has occured.
Uses
The myelin protein product has been shown to function as a substrate for protein kinases, one of the potential uses of myelin basic proteins (Yang, S. D. et al., J. Biol. Chem., 269 (1994) 29855-29859; Moriyama, T., et al., FEBS Lett., 353 (1994) 305-308). Moreover we have shown that this myelin basic protein product can be used in immunospot assays and T cell proliferation assays for the detection of the presence of antigen-specific T lymphocytes. The myelin basic protein product was shown to be effective also in induction of EAE in SJL mice.
In accordance with the afore mentioned, the myelin basic protein product of the present invention can be used for immunological studies which aim at understanding the pathogenesis of inflammatory demyelinating diseases, such as multiple sclerosis, in humans, and probably at the development of treatments of these diseases by oral tolerization.
TABLE 1______________________________________Expression of MBP isoforms in CNS of different speciesMolecular weight, kDaSpecies 21.5 20.2 18.5 17.2* 16.0 14.2 13 10______________________________________Mouse ++ + +++ +++ ++ ++++ +++ +Rat ++ + ++++ +++ ++ ++++ +++ ++G-pig ++ + ++++ + + + + -Rabbit + - ++++ + + + + -Chicken - - ++++ ++ ++ +++ °Human + - ++++ +++ +++ ++ + -Bovine +++ + ++++ +++ ++ + + -Swine +++ + ++++ +++ ++Fish# - - - - - ++++ +++ -______________________________________ *The 17.2 kDa form consists of two closely migrating forms #The 14.0 kDa form appeared as a duplicate, and an approximately 10 kDa band was visible in coomassie staining but not in immunoblot (see FIG. 1) °Band visible in coomassie staining, but not recognized by the polyclonal anti guineapig MBP serum. (-) not detected; (+) visible in immunoblot after extended exposure; (++) visible in immunoblot but not in coomassie staining; (+++) visible both i coomassie and immunostaining; (++++), strong coomassie and immunostaining
TABLE 2______________________________________Yield of MBP and isolation time in laboratory scalebefore lyophilization when using various methods YieldMethod mg/g Time Source______________________________________Present invention 2.8 3 h fresh porcine brain 1.4 3 h frozen porcine brain 1.4 3 h frozen mouse brain 5.5 3 h frozen mouse spinal cordBellini et al. 6.7 1 d fresh bovine white matterDeibler et al. 1.83 5 d frozen guinea pig brain 5.56 5 d frozen guinea pig spinal cordGiegerich et al. 1.65 2 d frozen human brain______________________________________ | A process for extraction of myelin basic protein from myelin containing tissue, such as central nervous system tissue, which process comprises the following steps:
extraction of the myelin basic protein from myelin containing tissue with an organic solvent selected from the group consisting of chloroform and compounds having a polarity similar to that of chloroform;
incubation of the organic phase in the presence of a lower aliphatic alcohol or propylene glycol;
transfer of the myelin basic protein from the lower aliphatic alcohol/organic solvent mixture to an aqueous phase with the aid of hydrogen ions (protons); and
recovery of the purified myelin basic protein. The invention also relates to the product obtainable by the process. | 8 |
RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Patent Application Ser. No. 60/850,714, entitled MULTIMEDIA CONTENT PRODUCTION AND PUBLICATION SYSTEM AND METHOD and filed 9 Oct. 2006, the disclosure of which is incorporated herein in its entirety by this reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to the field of website content production and distribution. More particularly, it concerns providing producers and publishers of multimedia content a convenient, end-to-end, monetizable production and distribution mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a schematic system block diagram that illustrates the invented Dynamic Media system architecture including the Dynamic Media Player in accordance with one embodiment of the invention.
[0004] FIG. 2 is a schematic block diagram of the Dynamic Media Model Player that forms a part of the system architecture in accordance with one embodiment of the invention.
[0005] FIG. 3 is a schematic block diagram that illustrates the invented viral adoption model in accordance with one embodiment of the invention.
[0006] FIG. 4 is a schematic functional block diagram that illustrates the invented Manager that forms a part of the system architecture in accordance with one embodiment of the invention.
[0007] FIG. 5 is an illustration of the look and feel and ease-of-use of the invented system to produce and publish rich-media content.
[0008] FIG. 6 illustrates how a rich-media Feed or Channel is produced, in accordance with the invented system.
[0009] FIG. 7 illustrates how the Web 2.0 technologies enable different social networking and user-created media and thus create an opportunity for rich-media syndication in accordance with the invention.
[0010] FIG. 8 illustrates operation of a Player Wizard that is a part of the invented system to produce a simple but rich-media Feed.
[0011] FIG. 9 lists examples of what can be produced, syndicated and published with the invented system.
[0012] FIG. 10 illustrates how private, public and commercial assets are centrally managed for compliance with the copyright laws.
[0013] FIGS. 11A-11H illustrate the Dynamic Media Model Player's translucent skin rendered visible by “mousing over” the window region of a webpage having the Dynamic Media Model Player of FIG. 2 embedded therein. Specifically, FIGS. 11A-11H illustrate a tutorial that illustrates various aspects of the use of the Player Console to Add an Item to a Show ( FIG. 11A ), Search a database, e.g. Flickr™, for photos to include therein ( FIG. 11B ), produce a Show by swapping or re-sequencing the Items within the Show ( FIG. 11C ), view Show Information including Properties ( FIG. 11D ), add Background Audio to a Show ( FIG. 11E ), Publish a Show ( FIG. 11F ), Select a Channel to which to assign the Show ( FIG. 11G ), and Publish the Show to a Player ( FIG. 11H ), all in accordance with the web-based, syndicated player apparatus, system and distribution methods of the invention.
[0014] FIG. 12 is a schematic block diagram that illustrates one possible Monetization Hierarchy or structure that may form a part of the system architecture in accordance with one embodiment of the invention.
[0015] FIG. 13 illustrates three different Syndication Finance Models that may be used in combination in accordance with one embodiment of the invention.
SUMMARY
[0016] A rich-media content production and syndicated distribution system includes a rich-media content production mechanism including one or more studio production tools for producing content including at least one of dynamic or static images, dynamic video or audio, text, HTML, mixed media presentation, Microsoft PowerPoint slides, Adobe PDF pages, etc., wherein the produced content resides on one or more proprietary servers remote from a user of the production studio, and a syndicated rich-media content distribution mechanism including one or more distribution tools for publishing such content to consumers, wherein the content production and content distribution mechanisms collectively enable two-way, end-to-end, produce-and-distribute capability.
[0017] An Internet-based rich-media content production system includes a rich-media content production mechanism including one or more studio production tools for producing content including at least one of dynamic or static images, dynamic video or audio, text, HTML, mixed media presentation, Microsoft PowerPoint slides, Adobe PDF pages, etc., wherein the produced rich-media content resides on one or more proprietary servers remote from a user of the production studio, and a rich-media content feed mechanism operatively coupled with the content production mechanism, the content feed mechanism enabling the delivery of the produced rich-media content into syndicated publication.
[0018] A syndicated rich-media content production and distribution method includes providing a producer's web-based studio mechanism for producing a channel containing one or more feeds or shows, each feed or show containing an item, the item containing a scene, the scene containing a rich-media asset; providing a publisher's web-based rich-media player for publishing a channel including the one or more feeds or shows within an Internet webpage; and providing for a web-based collaboration between a producer and a publisher by which the producer is induced to produce one or more feeds or shows targeted for the provisioned publisher's player or by which the publisher is induced to publish a provisioned producer's feed or show not so targeted.
[0019] In accordance with one embodiment of the invention, the channel is source (e.g. producer) and destination (e.g. publisher or viewer) agnostic, such that any one or more feeds or shows can be published and viewed on any one or more webpage-embedded media players. In accordance with one embodiment of the invention, the channel also is dynamic, since the feeds or shows viewable thereon are dynamically changeable by the producer of the feeds, shows and channel. Finally, in accordance with one embodiment of the invention, a publisher's webpage featuring a feed or show or channel automatically is updated by the producer if the producer decides to change his or her channel content.
[0020] Finally, a website-embeddable rich-media content player apparatus is described.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] QMIND™ and SPLASHCAST™ are trademarks owned by QMind, Inc. World-wide rights are reserved.
[0022] QMIND's dynamic SPLASHCAST™ media model is illustrated in FIG. 1 .
[0023] Novel SPLASHCAST™ media ‘players’ (hereinafter Players) such as Player 10 are defined by a website owner to provide a multimedia offering that can be embedded in a window or region 12 of a website for viewing and interaction by and with a viewer. The webpage typically resides on a third-party (3P) server (not shown). One or more Players 10 can be placed on any website, blog, or MySpace page. They can be displayed with no ‘skin’ (conventional player control borders that typically include pushbuttons and slide buttons, as well as prominent branding) so that instead they appear like traditional HTML images, as illustrated. (Skinless Player 10 illustrated in FIG. 1 is truly invisible in FIG. 1 , but will be understood to include the visible contents within window or region 12 as well as the Player functionality described below by reference to FIGS. 2 and 4 . FIGS. 11A-11H described below illustrates such an embedded Player 10 and its functionality including visible (e.g. opaque or translucent) pushbuttons, pop-up menus, and other controls.) Their controls, described below by reference to the SPLASHCAST™ Player Functional Diagram of FIG. 2 , will be understood to become visible when the Player is “moused over.” They optionally can have a subtle watermark-styled logo or “bug” (not shown i) in window or region 12 to cue the viewer to the fact that the window represents a dynamic media feed.
[0024] Skinless or unbranded Players like invented Player 10 heretofore are unheard of, but make sense in the context of the invention. This is because the owner of the website wants the media to “display” on his or her site but is uninterested in dedicating space for viewing controls, menus, and 3P branding.
[0025] One or more Players 10 can be centrally managed, as on one or more SPLASHCAST™ servers. They can be assigned media feeds that are created by other SPLASHCAST™ users. The players' contents can reside either on one or more SPLASHCAST™ servers or on one or more 3P servers. If they reside on 3P servers, then pointers thereto reside on a SPLASHCAST™ server for access to the 3P server-resident contents when the players are viewed or interacted with.
[0026] The media player dynamically pulls in media 14 selected by the webpage owner (“producer”) from any of the listed sources in the SPLASHCAST™ Dynamic Media list, as illustrated in FIG. 1 . Media 14 can be shared and syndicated among SPLASHCAST™ users. They can be centrally managed, as on one or more SPLASHCAST™ servers referred to herein as “proprietary” servers. They can be download-protected to preserve their integrity and distribution. They can be sold to other SPLASHCAST™ users. Central management of Media 14 on one or more proprietary servers ensures against down-load and provides needed control and regulation of Player 10 contents.
[0027] Thus, the invention features a dynamic media distribution structure in which producers and publishers are in a two-way, end-to-end, create-and-distribute relationship. So how can novel Player 10 forming a part of the invention become rapidly adopted for multimedia? By embedding it subtly ‘behind’ each and every dynamic media window or region 12 and by inviting any viewer first to subscribe to his or her very own Dynamic Media Player 10 . For free.
[0028] This is illustrated in the SPLASHCAST™ Player Functional Diagram of FIG. 2 . A Feed View block 26 represents that the viewer's cursor is ‘over’ dynamic media window or region 12 (this mouse position or cursor condition is referred to herein as “mouse-over”). Those of skill in the art will appreciate that, as used herein, mouse-over refers to any user-indicated cursor position relative to a display, whether indicated (“pointed at”) with a mouse or other pointing device such as a touch-sensitive screen, cursor control keypad or roller, voice command, etc., all of which mouse alternatives are contemplated for use in conjunction with the present invention and thus are within the spirit and scope thereof. Three options are provided:
[0029] 1) a Single Asset Item View menu 28 , e.g. of an Image (e.g. a JPG file), a Video (e.g. a FLV file), an Audio (MP3) file, a Multimedia (e.g. an SWF file) or an HTML or equivalent file. Those of skill in the art will appreciate that a Single Asset Item can take the form of a Single Scene 30 or a Filmstrip 32 . Those of skill also will appreciate that a Single Scene can be a single photograph, for example, whereas a Filmstrip can be an ordered or randomized temporal (sequential) display of plural photographs, for example.
[0030] 2) a SPLASHCAST™ Show Item Types menu 34 , e.g. of item types including 1) an External Feed 36 , 2) a Mashcast 38 and/or 3) a Studio Show 40 , any of which can take the form of multiple scenes in the form of a Slideshow (sequential use of the same space) or an Album (concurrent use of a shared space).
[0031] 3) a Player Menu 42 including, e.g. Get My Own Player (Subscribe) 44 , Subscribe/Acquire Item 46 , Manage My Players 48 , Flag 50 , Rate 52 , Comment 54 , View Comments 56 and Log out 58 .
[0032] Those of skill in the art will appreciate that more or fewer or different functions can be provided within the spirit and scope of the invention.
[0033] Some of the Player Menu 42 functional blocks can alternatively or additionally be accessed via a Log In/Register SPLASHCAST™ website 60 by those who already know about the multimedia revolution stirred by the invention. These visitors can Get My Own Player (subscribe) 44 , Subscribe/Acquire Item 46 , Manage My Players 48 and/or Comment 54 , as will be understood.
[0034] Flag 50 is used by the viewer of a player and by the SPLASHCAST™ server to flag Digital Millenium Copyright Act (DMCA)-defined objectionable or infringing material, enabling QMIND™ to take any required steps to delete the same from its servers. Rate 52 is used by viewers to rate a given Show or Feed 18 , e.g. using a star system (as from one to five), and a cumulative rating can be viewed by others. Comment simply allows viewers to comment on what they think of a Show or Channel. Alternative rating and/or comment means or methods are contemplated as being within the spirit and scope of the invention.
[0035] The rest of the functional blocks in FIG. 3 are self-explanatory, but it is emphasized that the prominence and order of the Get My Own Player block 44 encourages quick adoption and market penetration, making it very easy for QMIND™ to get new producers and publishers of multimedia content. Yet, despite the prominent availability of the Player 10 subscription option, the menu and controls are subtly hidden in skinless form ‘behind’ the dynamic media window itself and pop up only when moused over.
[0036] Those of skill in the art will appreciate that the invented SPLASHCAST™ Player 10 , when it becomes visible during mouse-over, can function like any other, e.g. it can have conventional click-on player controls such as start, stop, pause, fast-forward, rewind, etc. and it can, within the spirit and scope of the invention, have different or additional player controls and can look and feel differently from conventional players. FIGS. 11A-11H described below illustrate one contemplated embodiment of Player 10 in accordance with the invention.
[0037] In brief summary, the invented system architecture is configured such that the content resides either on SPLASHCAST™ servers accessible over the web or on 3P servers also accessible over the web via pointers residing in the SPLASHCAST™ servers. Because the content is web-based and because content for which QMIND™ is responsible resides in SPLASHCAST™ servers, its integrity is unsurpassed. In other words, the content within Players 10 is current, is never downloaded and thus un-copyable, virtually un-corruptible, and yet ubiquitously available to subscribers and other users. This centrally cast and content repository role of the proprietary SPLASHCAST™ servers, coupled with limited access to the invented system software invoked online and executing only at the proprietary SPLASHCAST™ servers creates end-to-end value for users while reducing risk. Thus, no actual SPLASHCAST™ code resides on any user's computer, instead only an HTML tag is pasted into the user's webpage on the user's server, giving the user access to all of the unique features of the invented system.
[0038] FIG. 3 illustrates the viral adoption model in accordance with one embodiment of the invention. Adoption of the SPLASHCAST™ system is referred to herein as viral because it typically grows exponentially rather than linearly. Thus, the outward spiral represented in background by a conch-like shell will be understood to go through timed phases. First, a critical number of production customers in the market are Seeded by providing them with a critical mass of SPLASHCAST™ Players 10 along with strong encouragement to adopt and produce content for their own website. Second, Website Visitors view the produced content in the SPLASHCAST™ Player 10 . Third, Viewers Adopt the SPLASHCAST™ Channel or Feed for their own website. Fourth, website Owners subscribe to Channels of interest and place (or re-publish) the subscribed Channel. Some website Owners decide to create new Channels and to produce and place (publish) new Channel content themselves using the simple and intuitive SPLASHCAST™ studio production tool suite. Fifth, other Website Visitors View Content in the SPLASHCAST™ Player 10 . Sixth, other Viewers Adopt the SPLASHCAST™ Channel for their own website by subscribing thereto. And so on and so on, with exponential growth in adoption by the marketplace.
[0039] FIG. 4 illustrates in block diagram form the behavior of the SPLASHCAST™ Manager software mechanism 62 that forms a part of the invented system architecture. A user logs in at 64 from a Player 10 moused-over window or region 12 and chooses any one or more of the many functions provided by the SPLASHCAST™ Console 66 .
[0040] SPLASHCAST™ Console 66 provides an elegant suite of soft tools in a studio environment that a producer visits online to Create an Item at block 70 . For example, the producer can Add Audio at block 72 , Add Images at block 74 , Add Video at block 76 , Add Text at block 78 and/or Add RSS Feed at block 80 . (RSS, or Really Simple Syndication, is a published standard for XML-based content organizers and sharers.) Such varied multimedia content can be added by Uploading at block 82 , by Searching at block 84 and/or by Recording content at block 86 . The producer then Defines the Properties at block 88 of the one or more added contents optionally including the monetization options for each at block 90 . In the Studio block 92 , the producer Sequences & Mixes Media to produce a desired multimedia content offering that may include one or more of the Audio, Images, Video, and Text or a single RSS Feed optionally added at blocks 72 , 74 , 76 , 78 and 80 , respectively. The add process can be repeated by the producer to Add More Media at block 94 .
[0041] When the producer is satisfied with the multimedia content, he or she Defines its Properties at block 96 so that it can be meta-tagged and later searched and, optionally, he or she Previews it at block 98 to ensure that it is ready to publish. The above steps can be repeated until the producer is satisfied that the multimedia content is ready to publish. When ready, the Created Show containing one or more Items or a single RSS Feed is Published to the Feed at block 100 . SPLASHCAST™ Console 66 also provides an elegant suite of soft tools that a publisher visits online to Publish a Feed at block 102 . These tools include Add Feed at block 104 , Manage Feeds at block 106 , Add Player at block 108 , and Manage Players at block 110 .
[0042] Add Feed 104 permits a publisher to Create (a) New (Feed) at block 112 , to Define the New Feed's Properties at block 114 , and to Create an Item at block 116 that is to be part of the New Feed 18 (refer briefly back to FIG. 2 ). (Those of skill in the art will appreciate that the Create an Item reference designators 70 and 116 refer to the same functional block). Add Feed 104 alternatively permits a publisher to Search SPLASHCAST™ at block 118 for an existing feed or to Select a Feed from the Feed Bin or repository at block 120 .
[0043] Manage Feeds block 106 permits a publisher to List All Feeds at block 122 , Define Properties at block 124 , choose Monetization Options at block 126 (as will be described further below by reference to FIGS. 12 and 13 ), View Stats (e.g. “hits” or number of views) at block 128 , Assign a Feed to a Player at block 130 , Delete a Feed at block 132 , List All Items in a Feed at block 134 , and Add Items to a Feed at block 136 . Add Items can include Create New Item at block 138 , Search SPLASHCAST™ at block 140 , and Select Item from Item Bin or repository at block 142 .
[0044] Add Player block 108 permits a publisher to Define Player Properties at block 144 and to Add a Feed to a Player at block 146 .
[0045] Finally, Manage Players block 110 permits a publisher to Define Player Properties at block 148 , View Player Stats at block 150 , Change Player Feed at block 152 , Manage Player URLs at block 154 , Get Embed Code for a given Player at block 156 , and Delete a Player at block 158 . Such Manage Players block 110 , within the scope and spirit of the invention, may have more, fewer or different attributes.
[0046] From the above description and illustrations herein, it will be appreciated that SPLASHCAST™ empowers non-technical individuals to personalize and publish all kinds of rich media dynamically to any website. SPLASHCAST™ enables website owners to sell or lease media real estate on their sites while also giving content owners a secure, online distribution channel.
[0047] SPLASHCAST™ technology makes it easy for individuals to find and create rich media on the web and then to syndicate it as an RSS feed, enabling others to easily add the content to their website or social networking page. Individuals now have a new outlet for creative self-expression, virtually without bounds in terms of the mixed media content they can create with SPLASHCAST™.
[0048] FIG. 6 illustrates the versatility of the invented system, wherein Interactive Mixed-Media so-called “MashCast” content 160 is augmented by Dynamic Video or Vlogs 162 ; Dynamic Images or Slideshows 164 ; Text Content, News, or Blogs 166 ; and Dynamic Audio, Music, or Podcasts 168 in relation to Skydiving for Dummies to create a Feed 18 suitable for publishing on a website having a window or region inhabited by a Player (e.g. Dynamic Media Player 10 embedded within window or region 12 as illustrated, but with different content, in FIG. 1 ).
[0000] With SPLASHCAST™, now, non-technical individuals can:
Create, publish, & syndicate a mixed media MashCast production; Produce high-quality music videos; Develop instructive tutorials and do-it-yourself content; Simplify podcasting and video blogging with “one-stop” production and publishing; Broadcast friends' content feeds on MySpace and other social network pages; and Much, much more . . .
[0055] The SPLASHCAST™ skinless web-based media Player 10 gives the site owner total control of how media appears on their webpage, while giving the owner of the content feed 18 complete control over what content is served up. Using SPLASHCAST™, anyone can easily add dynamic, centrally-managed rich media to their webpage; no mess, no fuss.
[0056] With twelve million blogs and counting, millions of photographs on Flickr, hundreds of thousands of videos on YouTube, and growing availability of non-restricted sound tracks, average people have access to massive amounts of media content-user created as well as professional—to make their websites and social network pages more expressive, interesting, informative, educational, or just fun.
[0057] But it is not easy for average people to personalize media aggregated from various sources, nor is it easy to publish the content directly to their website. It is even more difficult then to syndicate the content so that others with similar interests can incorporate it into their websites or social network pages. This is what SPLASHCAST™ enables anyone to accomplish.
[0058] FIG. 6 illustrates how straightforwardly a Feed or Channel 18 , e.g. the Skydiving for Dummies Feed featured in FIG. 5 , can be created, in accordance with the invention. The user
a) At 170 selects dynamic content from his or her computer and elsewhere, e.g. he or she downloads dynamic content from the Internet. Such content can include videos tagged as tandem/skydive, Google maps and RSS feeds about a skydiving school, pictures tagged as tandem/skydive jumping related, and music or other audio track; b) At 172 combines all such selected dynamic contents to produce an interactive MashCast that the user thinks is of interest to others; and c) At 174 publishes The MashCast Feed on any one or more websites or social network pages.
[0062] By empowering mere mortals to find, personalize, and syndicate media into dynamic feeds, QMIND™ is pursuing a bold, new model for content distribution on the web. Rather than forcing people to frequent destination sites for community, information, and media content, such can now be found on any web page and personalized by the web page owner. So one might see that cool video of twenty Elvises skydiving (recently posted on YouTube) appear on Mike's MySpace page, but now it is choreographed to “Heartbreak Hotel.” And on Kim's Skydiving for Dummies website, Kim's audio commentary explains how “one Elvis landed hard and broke his pelvis”. Meanwhile, the owner of the original video will be able to track how far and wide the video has been remixed and syndicated. As such, SPLASHCAST™ allows content owners the same kind of bragging rights for the popularity of their rich media that one sees today with popular blogs.
[0063] The evolution of the Web 2.0 phenomenon has had a significant impact on how people are using the Internet to communicate and express themselves. It has resulted in an explosion in the number of websites on the Internet. Young people are embracing social networks and everyone is uploading massive amounts of personal content of all kinds onto the Internet with the intent of sharing it with others. In this area, people use blogs as a platform or podium to express their thoughts, ideas, and opinions. They also use image sharing sites such as Yahoo's Flickr to share their photographs. A very recent and rapidly growing example of this kind of self-expression and sharing is exemplified by video sharing sites such as YouTube, which amazingly gets 100 million video views each day.
[0064] This migration to Web 2.0 has exponentially expanded the number of websites and the sources of content. In 1996 and the Web 1.0 world, there were forty-five million global users of some 250,000 websites and by far the highest percentage of content was published rather than user-generated (according to Dion Hinchcliffe's Web 2.0 Blog). A decade later, in 2006 and in the Web 2.0 world, one billion global users now substantially equally read and write on some eighty million websites.
[0065] In the context of blogs, podcasts, and news feeds, there has emerged a technical standard for syndication and distribution of content, that being industry-standard RSS (Really Simple Syndication). While it is not easy today for the non-technical populace to create or subscribe to RSS feeds, it has become a common mechanism for websites to subscribe to published content and for more sophisticated bloggers to make their content available via other websites.
[0066] The convergence that is occurring between these key Web 2.0 trends, social network sites for collaboration and rich media sites and blogs for sharing content, combined with the technical “plumbing” offered by RSS, has created the opportunity for QMIND™ to find novel ways to distribute user-generated content.
[0067] FIG. 7 illustrates how social networking and user-created media open wide the door for rich media syndication in accordance with the present invention by which a need for rich media syndication and monetization can be fulfilled. FIG. 7 shows that Web 2.0 Technologies enable digital media to benefit distribution, enable social networks to benefit connection, enable blogs to benefit communication, enable wikis to benefit collaboration, enable media sharing to benefit self-expression, and, in accordance with the present invention, finally now enable rich-media syndication.
[0068] QMIND's SPLASHCAST™ offering is designed around the concept of extreme simplicity of learning and use so that mere mortals can create cool, dynamic content, place it on their web pages, make it available for others to publish, and track how far it has spread on the Internet. This tracking feature, as well as a novel mapping feature, of the present invention will be further described below by reference to FIG. 11D .
[0069] The core of SPLASHCAST™ technology is in its ability to separate the display of content from the control of content, e.g. to separate the Player 10 from the Console 66 . Rather than using a static cut-and-paste or pointer approach, SPLASHCAST™ models its approach on that used for production of television, where one entity produces and controls the content in the show, syndicates it as a feed and makes it available over the network, and another entity displays the content by accessing and publishing the feed.
[0070] SPLASHCAST™ enables individuals to be producers to create a feed with professional-looking rich media content of their own or from anywhere on the Internet. With the explosion of user-generated content, a whole, new world of rich media is created. SPLASHCAST™ also makes it easy for anyone with a website, whether a personal site, a MySpace or Facebook page, a site for a community of interest, or a business site, to be a publisher and to incorporate such a Feed into the website to enhance its value and interest.
[0071] Central to the product offering is the SPLASHCAST™ Player. The SPLASHCAST™ Player is a FLASH-based web application. SPLASHCAST™ allows the owner of any web or social network page to “drop in” the Player and select a content feed for display. Unlike typical media players today that most are familiar with, the SPLASHCAST™ Player is 100% Internet-based, is simple for anyone to add to a webpage, and is simple for anyone to select his or her desired content from anywhere to display. This ease of use will be illustrated by reference below to FIGS. 11A-11H .
[0072] FIG. 8 illustrates the display of dynamic, centrally-managed rich media content using the invented SPLASHCAST™ Player 10 described herein. A SPLASHCAST™ Player Console 66 (refer briefly to FIG. 4 ) permits a user (e.g. one named Mike) to choose location and rules for dynamically pulling content for the illustrated Feed 18 about funny or silly photos. The user has chosen media type=photo, media location=Flickr, first criteria=tag “funny”, second criteria=tag “silly”, and third criteria=all collections to define his feed. The user's feed dynamically pulls photos matching the defined criteria from Flickr. The user employs the defined SPLASHCAST™ Feed or Channel 18 on his or her website in the SPLASHCAST™ Player 10 . Others see the user's Feed and add the SPLASHCAST™ Channel featuring the Player to their websites as well. Those of skill will appreciate that the SPLASHCAST™ Player 10 thus effectively inhabits a window or region 12 on a website, as illustrated in FIG. 8 .
[0073] Key to the design of the SPLASHCAST™ Player 10 is that it is simple, unobtrusive, and easy to embed into any website. The SPLASHCAST™ Player 10 will not have any “chrome”, so to speak; it will be “skinless.” This is a radical idea in the world of media players, but makes total sense from the perspective of the owner of the website. They want the media to “display” on their site but are uninterested in dedicating space for viewing controls, menus, and company branding. The SPLASHCAST™ Player 10 will simply display media in a window whenever possible.
[0074] Media-specific controls become visible and active on mouse-over, as appropriate, and also use a subtle watermark-style visual interface. The controls allow the visitor to control playback of the media as appropriate, and also provide a means to learn more about the Feed 18 , and how to use the SPLASHCAST™ Player 10 with this or another Feed 18 on one's own website. It is this last aspect, where viewers of a Feed 18 see how easy it is for them to add rich media content to their own website or social network page, wherein the power of viral growth comes into play. When one visits a website and sees a Player one is just a click away from a quick decision to get a Player.
[0075] While initially users may add SPLASHCAST™ Players 10 to their webpage because they would like to show a cool Feed 18 , they quickly will realize that it would be fun and easy to create their own custom Feed 18 . Thus, content for the SPLASHCAST™ Player 10 can be “programmed” using the SPLASHCAST™ Console 66 . The SPLASHCAST™ Player Console 66 is the simplest way for individuals to produce content for the SPLASHCAST™ Player 10 . It is an Internet-based application that makes it easy for a non-technical user to add specific dynamic content Feeds 18 , effectively creating a filter for content, to display and interact with in the Player 10 .
[0076] With the SPLASHCAST™ Player Console 66 being accessible directly from any place on the Internet, a user can simply create a custom feed from a media-sharing site such as Flickr or YouTube using a pre-defined set of available criteria (based for example on posting date, metadata tags, collection or set, etc.). So, for example, a SPLASHCAST™ Feed 18 might specify the “latest 10 videos posted to YouTube, with ratings>4 stars, with over 1,000 views, who's tags include “funny” or “comedy” or “silly”.”
[0077] SPLASHCAST™ Console 66 allows non-technical users to create more sophisticated rich media and interactive content feeds. SPLASHCAST™ Console 66 is also an Internet-based application, but it allows the user much greater flexibility in specifying, aggregating, displaying, and interacting with rich-media content. For instance, it helps in defining timing and effects for transitions, panning/zooming on images, and setting up interactive menus that can drive the display of text, images, video, and the play of sounds and music.
[0078] SPLASHCAST™ enables mere mortals to easily access and produce all kinds of rich-media content for themselves and others to simply drop into their websites. Today it is common for someone to add a song or a video or pictures to their websites. However, only commercial sites like CNN.com, SI.com, and the like have the technical wherewithal to provide dynamic, up-to-date content available from their syndicators for selection and viewing on their site by the public.
[0079] The present SPLASHCAST™ invention changes all this.
[0080] SPLASHCAST™ makes it easy for anyone to create or incorporate a video, image, audio, news or blog, or other RSS feed that is dynamic and will access content that the content producer specifies. Because public media sites like Flickr, YouTube, and others allow search and access of content based on tags and other filtering information, a SPLASHCAST™ Feed can serve up photos, for example, that have just been added to Flickr that have the same tags that the user has specified when producing the Feed. And any others with websites can then add that Feed to their own webpages without any programming expertise. They can also easily record narration for each slide and add a soundtrack to the entire slideshow. This creates a very powerful and broad-reaching paradigm for addressing the huge volume of rich media being created and the increasingly segmented communities of interest that frequent various websites.
[0081] Self-explanatory FIG. 9 illustrates the breadth of the options provided by the invention for creation (production), syndication and publication. Those of skill in the art will appreciate that rich multimedia contents now virtually limitlessly are subject to production, publication, and consumption.
[0082] QMIND's SPLASHCAST™ offering has the necessary ingredients for creating a viral adoption process and a corresponding exponential adoption curve. Rather than seeking to attract a user base to a destination site and compete with already established players in rich media and social networking, QMIND™ will use the power of syndication to enable the mass of participants in this ecosystem to consume a broad array of user-generated and premium content of interest.
[0083] The SPLASHCAST™ Player 10 is the key to the viral growth model, as mentioned above by reference to FIG. 3 . Viewers of content at websites and social network pages with SPLASHCAST™ Players 10 to display rich media content will see how easy it is to publish similar content on their own website or social network page. Just as people today add feeds for blogs to their sites on a massive scale, SPLASHCAST™ will expand this paradigm and enable feeds for rich media to be added via the simplicity and power of the SPLASHCAST™ Player 10 .
[0084] When viewing rich-media content on a website that is in a SPLASHCAST™ Player 10 , viewers are subtly presented with the choice of adding the Player 10 and its related content to webpages of their own. Once added, the users can easily create their own personalized rich-media Feeds 18 . They also can search for and choose from an array of content Feeds 18 that are available to play on their site. This will reinforce the cycle of creating new Feeds 18 and demonstrating the variety of content that is available to publish.
[0085] QMIND™ will initially focus on driving adoption of the Player 10 by encouraging individuals to use it to see how easy it can be to publish interesting, dynamic, free content from various video and image sharing sites, blogs, podcasts, and other RSS feeds on any other their websites or social networking pages. Over time, some content publishers will see the opportunity to monetize their website popularity by allocating some of their Internet real estate for paid promotion of rich-media content. As adoption of the Player reaches significant levels, there will be a corresponding increase in value of this as a distribution mechanism to owners of premium content. This will drive distribution of such content for payment by website publishers. Such a mechanism represents a new opportunity for premium content owners to expand into new distribution channels. Additionally, SPLASHCAST™ provides copyright owners the comfort of knowing exactly who is syndicating their content, what websites it appears on, how many times it has been accessed, and the security of knowing it can never be downloaded nor distributed outside the SPLASHCAST™ network.
[0086] The competitive environment surrounding social networking and media content is very busy. QMIND's competitive product distinction is that it provides value end-to-end, from rich media production to publishing, and in being agnostic to source and destination.
[0087] SPLASHCAST™ may be perceived as competing with rich-media production tools, user programmable “widgets”, and syndication services. While SPLASHCAST™ will offer some functionality that overlaps with such offerings, it is the combination of capabilities for design, syndication, and publishing of rich-media content that distinguishes QMIND's invented SPLASHCAST™ apparatus, system and method. To this end, the invented SPLASHCAST™ apparatus, system and method differentiate themselves from tools such as OneTrueMedia, Jumpcut, and Grouper for producing rich-media content. These services are primarily focused on video (and image) aggregation and editing, rather than the production, syndication, and monetization of the full spectrum of dynamic rich media.
[0088] QMIND™ will not focus on single-site or single-function applications, such as the plethora of “widgets” that have been developed for Google Desktop, blogs, and MySpace. While useful, these types of web-base applications lack the end-to-end value that will make SPLASHCAST™ compelling to (individual) publishers of user-generated content. Examples of these potential “widget” competitors include Stickam and TheSpringBox.
[0089] QMIND™ provides a simple yet comprehensive strategy to balance the rights/needs of the holders of copyrighted and valuable content with the dynamic sharing environment that has emerged for a lot of user-created content. The two elements of this strategy include, one, to treat media assets that are included into the SPLASHCAST™ network for use, and, two, to address the creation of media Feeds and their fair use.
[0090] Relative to media assets, SPLASHCAST™ distinguishes between existing assets that are already hosted on a sharing site that has already required the asset holder to assign a license type to the asset that dictates fair use. Some media sharing sites assign a default Creative Commons license type which can be altered by the asset owner. A QMIND™ user will be required to acknowledge via a click agreement that they will abide by the license terms under which a particular asset is shared.
[0091] SPLASHCAST™ users may also upload media assets of their own onto the SPLASHCAST™ site for their own use and/or for use by others in creating SPLASHCAST™ media Feeds. In this case, SPLASHCAST™ will assign a default Creative Commons license to each asset based on whether the asset is specified by the owner as private (meaning view-only to most but editable by the creator), public (usable, e.g. editable, by others at will for creating derivative works or Feeds), or commercial (usable by others, including others' Feeds in derivative works, for free or in accordance with a fee schedule). In the case of private assets, SPLASHCAST™ will assign an All Rights Reserved license. For both public and commercial assets, SPLASHCAST™ will assign an Attribution license.
[0092] FIG. 10 schematically illustrates how the invented system protects media assets and Feeds to protect owners and to ensure legitimate use of copyrighted assets. With the above discussion, FIG. 10 is believed to be self-explanatory.
[0093] FIGS. 11A-11H illustrate some of the user interface features of the SPLASHCAST™ Player 10 and production-and-syndicated-distribution methods in accordance with one embodiment of the invention. Those of skill in the art will appreciate that the user interface or so-called “look and feel” of the Player may be different, as is contemplated, yet within the spirit and scope of the invention. In FIG. 13A , Player 10 console 67 can be seen in the form of a tutorial to permit one or more Items such as photos to be Added, as obtained from a Flickr™ database search.
[0094] It will be appreciated by those skilled in the art that FIG. 11A is ‘skinless’, representing the fact that the user's mouse or cursor control device is outside the Player Console's rectangular boundaries.
[0095] FIGS. 11B through 11H in contrast illustrate the Player Console with its Player “frame” including command/control buttons and indicators more like conventional players. Those of skill will appreciate that, in accordance with one embodiment of the invention, the Player's skin is persistent for a short time, e.g. a couple of seconds, after the mouse exits the field. Those of skill in the art also will appreciate that it is the optionally skinless Player that renders a Rich-Media Player to be embedded discreetly within a webpage, as described herein.
[0096] FIG. 11B illustrates thumbnails of selected (check-marked) and non-selected photos therefrom to be saved as added Items. FIG. 13C illustrates the selected photos arranged in a sequence that can be clicked, dragged and dropped to change the original sequence to a revised sequence. FIG. 11C also illustrates the drop-down menu including the subscribe to channel, launch console, show info, comment, rate, flag, credits and e-mail show options that generally are described above by reference to FIG. 2 . FIG. 11D illustrates the show information window with the properties tab visible (behind which additional tabs provide for viewing of settings, statistics, channels, and maps). Those of skill will appreciate that keywords can be entered to assist in categorizing the show for later reference and/or use in topical searches by others. Those of skill also will appreciate that selecting the map tab opens a window that graphically identifies the geographies of persons who have viewed the show along with other viewer information. Fewer, different, or more tabs or features may be provided, within the spirit and scope of the invention.
[0097] FIG. 11E illustrates that there is presently no background audio for the show. Those of skill will appreciate that by clicking the choose audio button, the producer of the show very simply can choose an audio background (refer to FIG. 11A ). Thus the producer of a show can choose any combination of one or more audio, photo, video or text Feeds, or a single RSS Feed, to create multimedia content in the form of a Show.
[0098] FIG. 11F illustrates how a show is published by choosing a name for the show (“Outwardbound”); a playback template, e.g. Sequential, Auto-Advance v. click to advance; a transition for fades as between photos; a transition delay; and a random (shuffle) or sequential play presentation. FIG. 11G illustrates how the Player permits the producer of a Show to select a channel that will feature the Outwardbound Show, e.g. the default channel named My First Channel, its category and an indicator whether it is public or private. Finally, FIG. 11H illustrates to which Players the Outwardbound Show, which for the moment is the only Show in My First Channel, is published. For the moment, the published-to Player name is the default My First Player, of size 320×240 pixels, and the creation date is Tue. Jan. 23, 2007. Those of skill in the art will appreciate that, in accordance with one embodiment of the invention, Players are scalable.
[0099] Those of skill in the art will appreciate that channels can be thematic or can have some other “logic” or organization to them. For example, they can represent a period of time or a season, a favorite activity such as skiing or snowboarding, a place such as the outdoors, road trips, and thus can categorize Shows within the Channel as related in any desirable way. Accordingly, the Channel organization described herein is merely illustrative of the invention and is in now way limiting.
[0100] Those of skill also will appreciate that the Player HTML Tag window when moused over with a cursor contains the HTML code that, when copied to another's browser, provides a link to My First Player, where the published Outwardbound Show featured on My First Channel can be viewed (but not downloaded) by anyone familiar with or new to SPLASHCAST™.
[0101] Because media assets in SPLASHCAST™ cannot be downloaded by anyone (their consumption will be solely “on demand” for syndication or viewing, and not copyable), SPLASHCAST™ will be able to track asset usage and also to take an asset out of use (for example, if it is being used inappropriately or if the asset is considered not to meet the criteria required by QMIND™ (pornographic material, for instance)).
[0102] For media Feeds, the invention uses a similar licensing model as for media assets. SPLASHCAST™ Feeds can be private (again, meaning view-only but for the use/publishing by the creator), public (subscribable by others at will), or commercial (subscribable by others for free or in accordance with a fee schedule). Each of these classes of Feeds will be assigned the same Creative Commons license type as for similar assets. And creators of Feeds must further directly acknowledge via a click selection that their creation of the Feed meets with legitimate use criteria of any material that they may reuse, such as assets from Flickr, YouTube, and the like, and that the license for these assets in the Feed is based on that of the original copyright holder.
[0103] SPLASHCAST™ implements a number of operational procedures to ensure compliance with the Digital Millennium Copyright Act (DMCA). (The DMCA regulates the production and dissemination of technology capable of circumventing copyright protection measures. It also heightens penalties for copyright infringement on the Internet. Finally, the DMCA provides statutory “safe harbors” that avoid its potentially harsh results.)
[0104] When notified by the copyright holder of a media asset hosted on the SPLASHCAST™ asset site, or being published via a SPLASHCAST™ channel on a website, that it either was not posted by an authorized party or that its use in a feed is not in compliance with its licensing terms, SPLASHCAST™ will follow the processes defined by DMCA to remove the asset from its database or from the offending Feed, as requested. In order to comply with the Communications Decency Act, SPLASHCAST™ will monitor assets that are posted for use and delete those that are considered offensive or indecent, or which they have been notified of by others as being such.
[0105] This DMCA compliance goal is facilitated in accordance with the invention by the use of the SPLASHCAST™ Player's Flag functional block, as described above by reference to FIG. 2 .
[0106] QMIND™ will look to the adoption of the SPLASHCAST™ Player as a means of publishing dynamic rich-media content on websites and social networking pages as the key initial indicator and measurement of success. The SPLASHCAST™ viral growth model, as described earlier, is predicated on use of the Player on websites, resulting in exposure to a population of visitors to the website, resulting in adoption of the Player by said viewers, with the creation of new content feeds at all stages in this evolution.
[0107] But SPLASHCAST™ does not stop there. QMIND™ has also developed a new model for expanding the monetization of rich media on the web. First, media content owners can expand the distribution of their material to include websites and social network pages where there is a willingness to pay to publish premium content. Just as people are willing to pay separately today for ring-tones, website owners and those with social network pages will pay to incorporate their favorite music and TV episodes. Second, owners of popular websites can sell media real estate on their sites to content owners that are motivated to promote themselves and their work. Imagine all the garage bands that would be highly motivated and happy to pay popular music websites for the real estate to expose their music videos on these highly trafficked sites. Thus, over time, some content publishers will see the opportunity to monetize their website popularity by allocating some of their Internet real estate for paid promotion of rich-media content. As adoption of the Player reaches significant levels, there will be a corresponding increase in value of this as a distribution mechanism to owners of premium content. This will drive distribution of such content for payment by website publishers. Such a mechanism represents a new opportunity for premium content owners to expand into new distribution channels.
[0108] FIG. 12 illustrates a Content & Monetization Hierarchy or structure that optionally can be implemented in accordance with one embodiment of the invention. Those of skill in the art will appreciate that the illustrated structure is only one of many possible structures contemplated as being within the spirit and scope of the invention. Thus, FIG. 12 will be understood to be illustrative of one possible inventive aspect of the invention but not limiting in any way.
[0109] The “$$” in the upper right corner of Player block 16 represents money that can be earned by a Publisher of content. For example, a Publisher can lease or sell a Player 10 space (by use of what will be referred to herein as a “space-available mechanism”) within a website to a producer of high-value, premium content. The Producer is willing to pay for such Player 10 space because of the number of website visitors who will view or interact with the production. The “$$” in the upper right corner of singular Feed block 18 represents money that can be earned by a Producer or owner of content. (Those of skill will appreciate that, while only one Feed block 18 is shown per Player 10 , more than one can be provided, within the spirit and scope of the invention.) For example, a Producer can sell a production to a website owner for use in a Player 10 . The website owner is willing to pay for such a Feed 18 because the value of the website is enhanced by inclusion of the production. Feed 18 can include one or more Items 20 a , 20 b , and 20 c , or so-called “shows”, each of which can include one or more Scenes 22 a and 22 b , each of which can include one or more Media Assets 24 a , 24 b , and 24 c . The “$$” in the upper right corner of Media Assets blocks 24 a , 24 b , and 24 c represent money that can be earned by an owner of a Media Asset such as a photo, music, video, text, or other media 14 . Such Media Assets 24 a , 24 b , and 24 c are purchasable for value by the producer of Feed 18 that features them.
[0110] Those of skill in the art will appreciate that one or more Players 10 themselves may acquire marketable value as an Item such as Item 20 a . For example, one or more Players 10 in the form of one or more Items 20 , in accordance with one monetization model according to the invention, can be leased to advertisers for a price such as $25/1000 views ($25 CPM). In other words, the hierarchy or structure contemplates that a Producer can become an owner of Item 20 a , wherein the Item itself contains a multimedia content. Indeed, very involved customers of the invented Dynamic Media system may assume one or more roles concurrently or sequentially as the market and they themselves mature.
[0111] It is not a necessary part of the invented system architecture that every production or publication is a monetary event. For example, philanthropic or public service producers may not want money for their multimedia content contributions, they may instead simply want exposure or goodwill. Such exposure can be provided in such a transaction by a credits list appended to the end of a production, by a watermark or ‘bug’ logo or other discreet indicium overlaying the image, or by any other suitable means. Anonymity of contribution of course is also possible, with or without compensation to the contributor.
[0112] Those of skill in the art will appreciate that, in accordance with the embodiment of the invention illustrated in FIG. 12 , there is only one Feed 18 per Player 10 . This is a straightforward implementation and of course does not limit content in any way, since a producer or publisher can invoke a virtually unlimited number of Players 10 . Alternative implementations in which, for example, an unlimited number of Feeds 18 can be associated with each Player 10 are contemplated and are within the spirit and scope of the invention. Those of skill also will appreciate that sources for a Feed 18 can be the Producer him or herself or other Producers of content. QMIND's SPLASHCAST™ system will go to market with the intent to foster virtually no barriers to massive adoption of the SPLASHCAST™ Player. In order to facilitate this, the SPLASHCAST Player, and its companion products for selecting and designing content, are free.
[0113] This is illustrated in FIG. 13 , which shows in block diagram form three different monetization approaches including 1) Free Syndication, 2) Producer Pays for Promotion, and 3) Publisher Pays for Content, all but one of the three approaches economically linking Content from a Producer (on the left) with a particular Player subscription from a Publisher (on the right), thereby to provide monetary incentive and compensation as indicated by the broad arrows underneath approaches 2) and 3).
[0114] Unlike advertising-supported sites where monetization is derived from the population of the user base and its attractiveness to advertisers, QMIND™ will monetize its Internet services by enabling premium content producers to charge publishers for use of their streams and premium content publishers to charge producers to expose and promote their Feeds.
[0115] Once there is adoption and popularity for the SPLASHCAST™ Player, it is expected to see copyright owners of premium content making their content available to publishers to use for a fee. This kind of content can include anything from popular amateur videos, to independent music, to TV episodes, to commercial music videos. One possible business model reflects an average fee of $25 per 1,000 exposures (CPM). This is in line with similar fee structures used on the Internet.
[0116] Similarly, it is expected to see publishers that have popular sites, so-called premium publishers, getting paid by content producers to whom the exposure and promotion of their content is valued. Similarly, one possible business model assumes a fee structure where the average is also $25 CPM paid by the content producer. These valued publishers can include any kind of site that has built up a community of interest with substantial traffic.
[0117] In either case, QMIND™ would enter into a revenue-sharing agreement with premium producers and with premium publishers. This business model might be based on a 50/50 split for fees flowing in both directions. Those of skill in the art will appreciate that the revenue split is subject to change, thereby to respond to market conditions once there is a sufficient amount of interest in producing and publishing premium content with SPLASHCAST™.
[0118] Compensation as among a producer, a publisher and QMIND™ can also be automated. When a producer and a publisher reach agreement on subject matter, e.g. a Feed 18 or a Media Asset 24 a , 24 b or 24 c , the party owing the compensation pays QMIND™ based upon QMIND's log of viewings of each Feed 18 , Item 20 a , 20 b , 20 c , and Media Asset 24 a , 24 b , 24 c . QMIND™ takes its agreed percentage of the compensation and forwards the remaining agreed percentage, e.g. via PayPal™ or alternative suitable electronic or papered system, to the party owed under the compensation agreement. It will be understood that, under the two-way, end-to-end, producer-to-publisher Monetization Hierarchy or structure (refer briefly back to FIG. 12 ), a producer or a publisher or both can owe compensation under one agreement and be entitled to compensation under another. Either way, QMIND™ secures its compensation for providing the Dynamic Media Player 10 , server(s), rich-content production tool suite, syndicated distribution system and method, etc.
[0119] The invention enables copyright owners to secure, control, track, and even profit from the viral distribution of their media assets on the Internet. Those of skill will appreciate that alternative monetization and compensation schemes are contemplated. Thus, any suitable monetization or compensation scheme is deemed to be within the spirit and scope of the invention.
[0120] The invention thus empowers non-technical individuals to personalize and publish and syndicate all kinds of media content available on the web dynamically to any website. SPLASHCAST™ represents an exciting and timely opportunity to exploit the massive growth in rich media by making it available for mere mortals to easily publish on their websites and social network pages. In pursuit of this vision, QMIND™ has created a new model for monetization of rich-media assets. SPLASHCAST™ enables owners of popular websites to sell rich-media real estate on their sites while providing owners of valuable media content with an additional distribution channel to augment revenues.
[0121] Those of skill in the art will appreciate that the software architecture described and illustrated herein can be implemented in any suitable code by the use of any suitable coding and language tools. For example, C#, XML, Flash Actionscript, and SQL are a suitable suite of tools for coding the invented system software.
[0122] It will be understood that the present invention is not limited to the method or detail of construction, fabrication, material, application or use described and illustrated herein. Indeed, any suitable variation of fabrication, use, or application is contemplated as an alternative embodiment, and thus is within the spirit and scope, of the invention.
[0123] It is further intended that any other embodiments of the present invention that result from any changes in application or method of use or operation, method of manufacture, shape, size, or material which are not specified within the detailed written description or illustrations contained herein yet are considered apparent or obvious to one skilled in the art are within the scope of the present invention.
[0124] Finally, those of skill in the art will appreciate that the invented method, system and apparatus described and illustrated herein may be implemented in software, firmware or hardware, or any suitable combination thereof. Preferably, the method system and apparatus are implemented in a combination of the three, for purposes of low cost and flexibility. Thus, those of skill in the art will appreciate that the method, system and apparatus of the invention may be implemented by a computer or microprocessor process in which instructions are executed, the instructions being stored for execution on a computer-readable medium and being executed by any suitable instruction processor.
[0125] Accordingly, while the present invention has been shown and described with reference to the foregoing embodiments of the invented apparatus, it will be apparent to those skilled in the art that other changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined in the appended claims. | A rich-media content production and distribution system includes a rich-media content production mechanism including a one or more studio production tools for producing content including at least one of dynamic or static images, dynamic video or audio, text, HTML, mixed media presentation, Microsoft PowerPoint slides, Adobe PDF pages, etc., wherein the produced content resides on one or more proprietary servers remote from a user of the production studio, and a syndicated rich-media content distribution mechanism including one or more distribution tools for publishing such content to consumers, wherein the content production and content distribution mechanisms collectively enable two-way, end-to-end, produce-and-distribute capability. An Internet-based rich-media content production system and syndicated rich-media content production and distribution methods also are described. Finally, a website-embeddable rich-media content player apparatus is described. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to a method and a device for regulating individual sub-flows of a system for conveying fluid media in accordance with the introductory portion of claims 1 and 7 .
In systems for conveying fluid media with several parallel conveying lines, the generation of pressure is responsible for the transport of the medium. Frequently, it is necessary that the individual sub-flows, arriving at the respective conveying destination, are of the same or of a known magnitude. In such a case, it must be possible to adjust the deviating flow resistances.
The possibility of temporally coordinating the volumes (or masses), arriving at the conveying destination, is particularly important if the composition of the fluid medium is selectively inhomogeneous or if the fluid medium is a carrier for substances, which are to be transported discontinuously. Even if, during the conveying of liquid media, exact quantitative doses or also analytical determinations of a possibly changing composition in the individual conveying lines of a conveying system are required, unforeseeable flow rate times can create problems. For example, in the area of the food industry, of medical technology and also of the pharmaceutical industry, it is frequently necessary to supply certain volumes simultaneously to a particular conveying destination. In practice, different and, in some cases also, temporally changing flow resistances in the individual conveying lines stand in the way of this necessity. These different flow resistances arise due to different frictional losses in the line system and result, for example, from material defects, different flow cross sections or also blockages. For example, in the area of the food industry, of medical technology and also of the pharmaceutical industry, it is frequently necessary to supply certain volumes simultaneously to a particular conveying destination. In practice, different and, in some cases also, temporally changing flow resistances in the individual conveying lines stand in the way of this necessity. These different flow resistances arise due to different frictional losses in the line system and result, for example, from material defects, different flow cross sections or also blockages.
Until now, only the control of the pressure in the individual conveying lines was known. An example of this is shown in the U.S. Pat. No. 2,676,603. The apparatus, shown there, works with several restricting capillaries, which are brought to the same pressure level at the outlet side. The volume flows emitted are the same only at identical pressures in the discharging chambers described there, at identical pre-pressure, at identical temperature and with identical restricting capillaries. The control namely functions only if the respective counter-pressures of the units, which are to be supplied (in the case shown there of an internal combustion engine, the pressure drop at the fuel pipelines plus the drop in the intake manifold when the inlet valve is opened), are small in comparison to the regulator dwell pressure. If these counter pressures exceed a certain limiting value, the control is made inoperative and the volume flows adjust corresponding to the respective counter-pressure. In addition, the control does not notice if one of the restricting capillaries has an increased flow resistance, for example, because of a blockage. In the blocked restricting capillary, there is then a correspondingly smaller volume flow, while the pressure drop is the same.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a method and a device, with which it is possible to regulate the sub-flows of the individual conveying lines of a conveying system for fluid media, as required, with only a single constant conveying unit.
This objective is accomplished with the characterizing distinguishing features of claims 1 and 7 .
Advantageous further developments are given in the dependent claims.
An essential distinguishing feature of the method described here is the determination of partial flow resistances from the ratio of a total pressure P, measured before the distribution, and a sub-flow value S,, determined in each conveying line. The latter could not be attained without including the total pressure and the direct control on the sub-flow at constant total flow.
For the selection of the total pressure sensor, which determines the pressure P ahead of the distribution over the individual conveying lines, the permissible range of the total flow, as well as the possible changes in the viscosity of the conveying medium are of decisive importance. The selection of an advantageous measurement principle for determining the sub-flow value S n depends on the particular application.
Different methods are known for measuring volume and mass flows. Criteria for the selection of flow-through measuring devices are set down in DIN 2644.
The advantages of the invention lie in the possibility of producing with the method and the device identical or selectively different sub-flows for fluid media in the conveying lines in a conveying system using a single conveying unit (such as a pump).
Each of the control devices, working strandwise, can undertake the approach of the actual value to the specified value without interference from the control processes in the other conveying lines. In contrast to this, with direct regulation of the sub-flows using a flow meter and a control valve, interference by the control processes in the other conveying lines would be unavoidable. Overall, because a constant flow is supplied, it would not be possible to control the sub-flow.
For the methods described, the conveying output and conveying pressure can be varied without disturbing the controlled equilibrium. For applications with a viscosity that varies, the specified value can be adjusted independently of the viscosity by a suitable selection and a suitable installation of the sub-flow unit.
A further, important advantage of the invention consists of determining changes in the flow resistance of individual conveying lines, which occur suddenly or slowly during the operation, for example, due to blockages during the transport of dispersions or in the case of leaks in a conveying line. If a permitted control value range is set for the valve used, the above-mentioned disturbances can be noted in good time and the conveying lines in question switched out.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in greater detail in the following by means of examples and drawings, in which
FIG. 1 a shows a first diagrammatic representation of the arrangement of the regulating device in a conveying line, the sub-flow unit and the throttling site B of the valve ( 7 ) being disposed ahead of the flow resistance,
FIG. 1 b a second diagrammatic representation of the arrangement of the regulating device in a conveying line, the sub-flow unit and the throttling site B of the valve ( 7 ) being disposed behind the flow resistance,
FIG. 1 c a third diagrammatic representation of the arrangement of the regulating device in a conveying line, the sub-flow unit being disposed ahead of and the throttling site B of the valve ( 7 ) being disposed behind of the flow resistance,
FIG. 1 d shows a fourth diagrammatic representation of the arrangement of the regulating device in a conveying line, the sub-flow unit being disposed behind and the throttling site B of the valve ( 7 ) being disposed ahead of the flow resistance,
FIG. 2 a shows a first diagrammatic variation of the arrangement of the regulating device with sub-flow measurement by pressure difference in a conveying system,
FIG. 2 b shows a second diagrammatic variation of the arrangement of the regulating device with sub-flow measurement by pressure difference in a conveying system,
FIG. 2 c shows a third diagrammatic variation of the arrangement of the regulating device with sub-flow measurement by pressure difference in a conveying system,
FIG. 2 d shows a fourth diagrammatic variation of the arrangement of the regulating device with sub-flow measurement by pressure difference in a conveying system,
FIG. 2 e shows a fifth diagrammatic variation of the arrangement of the regulating device with sub-flow measurement by pressure difference in a conveying system,
FIG. 2 f shows a sixth diagrammatic variation of the arrangement of the regulating device with sub-flow measurement by pressure difference in a conveying system,
FIG. 3 shows a graphic representation of an indirect regulation of the volume flow, realized with a variation of the arrangement of FIG. 2 a , in a four-channel liquid chromatography device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 a to 1 d , an inventive regulating device is described diagrammatically. It is disposed in a conveying line 11 of a multi-channel conveying system and the course of its functioning is shown. For purposes of clarity, only conveying line. 11 is shown here for explaining the device.
The total pressure, produced by a conveying unit 9 (with constant flow control 13 of the conveying system, drives a sub-flow of a fluid phase (medium) for the conveying line 11 in question. In FIG. 1 a , this sub-flow, after the distribution 8 through the sub-flow measuring unit D and, after that, over the throttling site B of the valve 7 , flows through the flow resistance 1 . A total pressure measuring device 10 , which is disposed at the outlet side of the conveying unit 9 , determines the pressure P, dropping off at the total system. The ratio of this pressure to a sub-flow value S n , determined in each conveying line 11 , represents an actual value of the flow resistance numeral 1 for the conveying line under consideration. In the actual value determination 4 of the data acquisition, processing and control value output module C, this ratio is calculated as actual value and supplied to the comparison site A (actual value—specified value) of the data acquisition processing and control value output module C. From the so-called actual value and a value specified by a specified value output part 5 , a control difference is calculated, which controls the control process over the controller 6 and the valve 7 .
FIGS. 1 b to 1 d shows further possible variations of the arrangement for this embodiment of the invention.
In accordance with a further embodiment of the invention shown in FIGS. 2 a to 2 f , the sub-flow is determined by means of a pressure drop, which is directly proportional to the sub-flow, at a measurement capillary 2 , which is disposed serially to the flow resistance numeral 1 . This pressure drop is determined from the difference between two precious. In a preferred variation of the arrangement of this special embodiment of the invention, which is shown in FIG. 2 a , this pressure drop is represented by the difference between the pressure at the total pressure metering device 10 and the partial pressure metering device 3 (ΔP measurement capillary =P−P measurement capillary ). The above ratio therefore is calculated accordingly from the total pressure P and the pressure difference at the measurement capillary.
FIG. 2 b to FIG. 2 f shows further possible variations of this special embodiment of the invention.
The special embodiment mentioned (FIG. 2 a to FIG. 2 f ) with measurement of the sub-flow by measuring the difference in pressure, because of this special importance for the control method described, are explained in greater detail below for equipment with eight conveying lines.
The conveyed liquid phase is distributed by means of a distributor 8 to, for example, eight conveying lines, which extend parallel to one another. In each conveying line, flow resistances 1 . 1 to 1 . 8 are shown diagrammatically.
In the above-mentioned preferred special variation of the invention of FIG. 2 a , the valves 7 . 1 to 7 . 8 , the partial pressure measuring devices 3 . 1 to 3 . 8 and the measurement capillaries 2 . 1 to 2 . 8 are ahead of the respective flow resistance 1 . 1 to 1 . 8
In FIG. 2 b , the valves 7 . 1 to 7 . 8 are disposed at the inlet side and the partial pressure measuring devices 3 . 1 to 3 . 8 , as well as the measurement capillaries 2 . 1 to 2 . 8 are disposed at the outlet side of the flow resistances 1 . 1 to 1 . 8 . The measurement capillaries here are at the outlet side at the same pressure level (such as atmospheric pressure).
According to FIG. 2 c , the complete arrangement of the partial pressure measuring devices 3 . 1 to 3 . 8 , the measurement capillaries 2 . 1 to 2 . 8 and of the valves 7 . 1 to 7 . 8 is also possible at the outlet side of the flow resistances 1 . 1 to 1 . 8 . Moreover, the measurement capillaries at the outlet side are at the same pressure level (such as atmospheric pressure).
In any further variation, shown in FIG. 2 d , in a reversal of the arrangement of FIG. 2 b , the possibility is provided pursuant to the invention of disposing the partial pressure metering devices 3 . 1 to 3 . 8 and the measurement capillaries 2 . 1 to 2 . 8 at the inlet side and the valves 7 . 1 to 7 . 8 at the outlet side of the flow resistances 1 . 1 to 1 . 8 . The measurement capillaries here are at the inlet side at the same total pressure level, which is measured by the total pressure measuring device 10 ahead of the distribution.
According to FIG. 2 e , the valves 7 . 1 to 7 . 8 and the measurement capillaries 2 . 1 to 2 . 8 are disposed at the input side of the flow resistances 1 . 1 to 1 . 8 . The pressure drop at the measurement capillaries is determined in each case by means of two separate partial pressure measuring devices of the same type 12 . 1 to 12 . 8 and 3 . 1 to 3 . 8 .
A further exchange of the measurement capillaries 2 . 1 to 2 . 8 , disposed at the outlet side of the flow resistances, and of the valves 7 . 1 to 7 . 8 in FIG. 2 f , with respect to the representation of FIG. 2 c , is possible. The pressure drop at the measurement capillaries (difference in pressure) is determined in each case by means of two separate partial pressure metering devices of the same type 12 . 1 to 12 . 8 and 3 . 1 to 3 . 8 .
The embodiments of the inventive device, shown in FIG. 2 a , FIG. 2 d and FIG. 2 e , are suitable especially for the operation with a fluid medium of changing viscosity, since the sites where the total pressure and partial pressure are measured, are spatially close to one another.
This possibility of arranging the regulating devise in a conveying system flexibly is associated with many advantages with respect to the structure for different fields of application.
In FIG. 3, the volume flows of four parallel separating lines of a liquid chromatograph are shown. The curves show the advantageous effect of the inventive, indirect volume flow control. The values of four different volume flows in single conveying lines rapidly approach a common value when and the control is switched on.
Since a sub-flow determination by measuring the difference in pressure at a measurement capillary is advantageous for many applications, a computational model is given in below for this already mentioned special, preferred embodiment of FIG. 2 a . A consideration of the simple physical laws makes the relationships clear. It is assumed that the flow of the liquid is laminar and obeys the linear flow law. For an understanding, it is sufficient to describe only a single conveying line of n conveying lines. A conveying line consists, in this connection, consists of an arrangement for measuring the sub-flows by means of a measurement capillary, a valve for controlling and a main flow resistance. In the simplest case, it is assumed that there is one pipeline for this flow resistance (the corresponding applies for other flow resistances). R index refers to the flow resistances, Δp to the pressure drops, η to the viscosity of the liquid medium and V to the volume flow. (Further abbreviations will be explained with the formulas).
For the individual flow resistances of the considered conveying line E of the conveying system shown in FIG. 2 a , the following expressions result: R measurement capillary ( 2.1 ) = Δ P measurement capillary V sub = 8 η l π r 4
in which l=the length of the capillary and r=the internal radius of the capillary R valve ( 7.1 ) = Δ P valve V sub = 6 η π s 3 G
in which s=the gap width, G=a geometric factor (depending on the type of valve) R pipeline ( 1.1 ) = Δ P pipeline V sub = 8 η L π R 4
in which L length of the pipeline and R=the internal radius of the pipeline
With the resulting total pressure ahead of the distribution
P=ΔP
measurement capillary
+ΔP
valve
+ΔP
pipeline
it is possible to write for the total flow resistance R total of the conveying line in question R total = P V sub = 8 η l π r 4 + 6 η π s 3 G + 8 η L π R 4
Since V sub = π r 4 8 η l Δ P measurement capillary = π r 4 8 η l ( P - P measurement capillary )
the following can be written for the total flow resistance of the conveying line: R total = ( 8 η l π r 4 ) P P - P measurement capillary = R measurement capillary + R valve + R pipeline
If the temperature is the same everywhere in the equipment, the viscosity η=f(T)=const. can be eliminated from all the elements and the following relationship results R total = P P - P measurement capillaryl π r 4 8 l ( 8 l π r 4 + 6 G π s 3 + 8 L π R 4 )
by means of which the measurable pressure ratio P/(P−P measurement capillary ) becomes equal to an expression consisting of geometric quantities. The term in parenthesis for the valve permits all sub-flow resistances to be matched (uniformity of the sub-flows) or specified deviations hereof to be adjusted during the regulating process over the gap width s for each of the n conveying lines. The sub-flows, present after the flow resistances are regulated, are inversely proportional to the flow resistance of the conveying line.
The invention described is used for indirectly regulating the flow in liquid chromatography equipment, as shown in FIG. 3 and realized in FIG. 2 b . The chromatography column, which is filled with spherical particles, is to be regarded as the main flow resistance of the conveying lines. The flow resistance of a chromatography column can be described as follows: R chromatography column = Δ P chromotography column V sub = χη H d k 2 D 2
in which χ is a dimensionless constant, H is the height of the column, D is the diameter of the column and d k is the diameter of the particles.
For the flow resistance values R total in a conveying line, which are to be regulated, the following relationship can be formulated after the viscosity is eliminated: R total = P P - P measuring capillary = π r 4 8 l ( 8 l π r 4 + 6 G π s 3 + χ H d k 2 D 2 )
With the resulting total pressure ahead of the distribution
P=ΔP
measurement capillary
+ΔP
valve
+ΔP
pipeline
it is possible to write for the total flow resistance R total of the conveying line in question R total = P V sub = 8 η l π r 4 + 6 η π s 3 G + 8 η L π R 4
Since V sub = π r 4 8 η l Δ P measurement capillary = π r 4 8 η l ( P - P measurement capillary )
the following can be written for the total flow resistance of the conveying line: R total = ( 8 η l π r 4 ) P P - P measurement capillary = R measurement capillary + R valve + R pipeline
If the temperature is the same everywhere in the equipment, the viscosity η=f(T)=const. can be eliminated from all the elements and the following relationship results P P - P measurement capillaryl π r 4 8 l ( 8 l π r 4 + 6 G π s 3 + 8 L π R 4 )
by means of which the measurable pressure ratio P/(P−P measurement capillary ) becomes equal to an expression consisting of geometric quantities.. The term in parenthesis for the valve permits all sub-flow resistances to be matched (uniformity of the sub-flows) or specified deviations hereof to be adjusted during the regulating process over the gap width s for each of the n conveying lines. The sub-flows, present after the flow resistances are regulated, are inversely proportional to the flow resistance of the conveying line.
The invention described is used for indirectly regulating the flow in liquid chromatography equipment, as shown in FIG. 3 and realized in FIG. 2 b . The chromatography column, which is filled with spherical particles, is to be regarded as the main flow resistance of the conveying lines. The flow resistance of a chromatography column can be described as follows: R chromatography column = Δ P chromotography column V sub = χ η H d k 2 D 2
in which χ is a dimensionless constant, H is the height of the column, D is the diameter of the column and d k is the diameter of the particles.
For the flow resistance values R total in a conveying line, which are to be regulated, the following relationship can be formulated after the viscosity is eliminated: P P - P measuring capillary = π r 4 8 l ( 8 l π r 4 + 6 G π s 3 + χ H d k 2 D 2 )
The measurable pressure ratio P/(P−P measurement capillary ) here also becomes equal to an expression of geometric quantities. In this case, the valves are selected so that equalization of the flow resistance R total can be reached during the regulating process. | The invention relates a method and a device for regulating individual sub-flows of a conveying system while the main flow is conveyed in a constant manner. The aim of the invention is to provide a method and a device which enable the sub-flows of the conveying lines of a system for conveying fluid media to be regulated as required in said individual conveying lines with just one conveyor unit. To this end, the inventive device for regulating individual sub-flows of a system for conveying fluid media has several conveying lines which are guided in parallel. The invention is characterized in that the following are arranged in the conveying system: at least one total pressure measuring device ( 10 ), at least one sub-flow measuring unit (D) in each conveying line, at least one valve ( 7 ) with a throttle (B) and a data acquisition, processing and control value output module (C), these being functionally interconnected by hardware and/or software. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
The following application is incorporated by reference: U.S. Patent Application Ser. No. 62/018,136, filed Jun. 27, 2014. If there are any contradictions or inconsistencies in language between the present application and the application incorporated by reference that might affect the interpretation of the claims in the present application, the claims herein should be interpreted to be consistent with the language herein.
FIELD OF THE INVENTION
The present invention relates to motorized systems in general, and, more particularly, to a motorized window-blind system with position calibration, circuit protection, and detection of motor stoppage.
BACKGROUND OF THE INVENTION
Many household devices and appliances enable a user ahead of time to configure them to operate in a customized manner. For example, a smart-switch device can be programmed to control a first light based on one combination of button pushes and a nearby, second light based on another combination. As another example, a coffeemaker appliance can be programmed to make automatically coffee at 7:00 am on some mornings and 9:00 am on others.
The configuring of some such devices and appliances can be clumsy, however. Some smart switches, for instance, only enable programming by having the user tap in various sequences on the switch itself. Yet, this clumsiness in programming has been addressed somewhat. A software application, or “app”, running on a Bluetooth-enabled or WiFi-enabled smartphone can provide a keyboard on the phone display; the smartphone user configures the device or appliance by using the keyboard, and the app translates these user interactions into commands that are transmitted wirelessly to the device or appliance.
The aforementioned combination of smartphone, app, and wireless capability has addressed some of the configuring problems and for some types of appliances, but not all. Some appliances require a training procedure such as calibration, including appliances that comprise one or more electromechanical systems such as a motor. In such appliances, the motor might need to be calibrated by operating it across at least one complete cycle of operation. One such application of a motor is in a motorized window blind, which uses a motor to raise and lower the blind, where moving the blind from being fully opened to fully closed to fully opened again constitutes one complete cycle. Calibration on such a device might be necessary in order to determine how to select an intermediate position for the blind, instead of merely allowing the blind to move to its extreme positions—that is, up or down all the way. Another reason for calibration is to support a progress bar when the blind is being moved from one position to another, even from one extreme position to the other.
In regard to calibrating a motorized blind or similar system, a user is typically prompted to press a button that controls the motor in a first direction, whereupon the blind travels from one extreme to the other extreme. Then, the user releases the button when the blind has stopped travelling, when prompted to do so. The user is then prompted to press a button controlling the motor in the opposite direction and is prompted to release the button when the blind has travelled back to its original position.
Various difficulties still exist with calibration, however. A first problem with the aforementioned calibration procedure is that it is often perceived as inconvenient to the user. Although the procedure might seem straightforward, it still involves a human user, which inherently makes the calibration process prone to error.
In addition, the controllers of such motorized systems comprise electronics that can be damaged if the driving motor is not carefully turned on, turned off, or reversed in direction. For example, some motorized window blinds are conventionally driven with a motor that has a double winding and is powered by alternating current (AC) line voltage, or “mains” voltage. The two windings in the motor respectively drive upward motion and downward motion in the window blind. The motor has built-in limit switches that cut off power when the blind reaches the top or bottom position. When the blind is raised and reaches the topmost position, the winding that powers the upward movement is cut off. Similarly, when the blind is lowered and reaches the bottommost position, the winding that powers the downward movement is cut off. Although the limit switches perform these important functions, they can also introduce problems in the controlling circuitry.
Finally, some of the costs associated the controllers of some prior-art motorized systems are excessive and need to be lowered in order to promote additional acceptance by the consumer of such systems.
SUMMARY OF THE INVENTION
The present invention enables a motorized system with improved calibration, circuit protection, and detection of motor stoppage than in some motorized systems in the prior art. The improvements that are disclosed herein can be applied to a motorized window-blind system, which is featured in this specification, as well as to other motorized systems, within households and elsewhere.
In accordance with the illustrative embodiment of the present invention, a power-switching circuit is disclosed that addresses the problem of certain electronic components being subjected to voltage spikes when the driving motor is turned on, turned off, or reversed in direction. The circuit is disclosed herein that comprises a TRIAC, or “triode for alternating current,” and TVS diodes, or “transient-voltage-suppression diodes,” providing voltage protection to various types of electronic components, including while not being limited to control components of alternating-current (AC) motors.
In accordance with the illustrative embodiment of the present invention, a controller is disclosed that provides a cost advantage over at least some controllers in the prior art, in particular for those of AC motors. The controller disclosed herein features measurement of voltage that is induced on a secondary winding of a motor, in contrast to or in addition to measuring electrical current that is present at a primary winding of the motor. The controller measures the voltage in order to detect certain events that occur during the operation of the motor, including while not being limited to motor stoppage.
A calibration method disclosed herein of a motorized system, illustratively a motorized window blind, can account for one or both of the aforementioned protection circuit and event-detecting controller. The disclosed calibration method accounts for human interaction and, in doing so, is intended toward making a calibration process of a motorized household system less prone to human error.
An illustrative control system comprises: a first terminal of a controller, the first terminal being electrically connectable to a first end of a first winding of a motor having a shaft, wherein voltage being applied via the first terminal to the first end of the first winding in relation to a second end of the first winding results in rotation of the shaft in a first rotation direction; a second terminal of the controller, the second terminal being electrically connectable to a first end of a second winding of the motor, wherein voltage being applied via the second terminal to the first end of the second winding in relation to a second end of the second winding results in rotation of the shaft in a second rotation direction; a third terminal of the controller, the third terminal being electrically connectable to the second end of the first winding and the second end of the second winding; a detector of the controller, the detector being configured to detect a decrease in magnitude of voltage across the second and third terminals when voltage is being applied at the first end of the first winding; and a processor of the controller, the processor being configured to output a first signal based on the detector detecting the decrease across the second and third terminals.
An illustrative method for controlling a motor by a controller, the motor having i) a shaft, ii) a first winding, and iii) a second winding, the controller having i) a first terminal that is electrically connected to a first end of the first winding, ii) a second terminal that is electrically connected to a first end of the second winding, and iii) a third terminal that is electrically connected to a) a second end of the first winding and b) a second end of the second winding, comprises: applying, by the controller, predetermined voltage via the first terminal to the first end of the first winding in relation to the second end of the first winding such that the motor shaft rotates in a first rotation direction; detecting, by the controller, a decrease in magnitude of voltage across the second and third terminals when voltage is being applied at the first end of the first winding; and generating, by the controller, a first signal based on the decrease detected across the second and third terminals.
An illustrative method for calibration comprises: receiving, by a controller, a first command to calibrate a motorized device that is mechanically coupled to a shaft of a motor; actuating the motor, by the controller providing voltage at a first winding of the motor, based on receiving the first command, wherein the actuating is such that the shaft rotates in a first direction moving the motorized device from a first position toward a second position; detecting, by the controller, that the motorized device reaches the second position; actuating the motor, by the controller providing voltage at a second winding of the motor, wherein the actuating is such that the shaft rotates in a second direction moving the motorized device from the second position toward the first position; detecting, by the controller, that the motorized device reaches the first position; transmitting a message based on the detecting of the motorized device reaching the first position.
An illustrative circuit comprises: a first triode for alternating current (TRIAC) having an MT 1 terminal, an MT 2 terminal, and a gate; a first transient-voltage-suppression (TVS) diode having i) a first terminal electrically coupled to the MT 2 terminal of the TRIAC and ii) a second terminal; and a second TVS diode having i) a first terminal electrically coupled to the second terminal of the first TVS diode and ii) a second terminal electrically coupled to the MT 1 terminal of the TRIAC; wherein the first TRIAC conducts electrical current if a predetermined voltage across the second TVS diode is exceeded.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B depicts a picture of motorized system 100 in accordance with the illustrative embodiment of the present invention.
FIG. 2 a schematic diagram of motorized system 200 in accordance with the illustrative embodiment of the present invention.
FIG. 3 depicts motor 201 of system 200 .
FIG. 4 depicts controller 204 of system 200 .
FIG. 5 depicts a block diagram of the salient components of microcontroller unit 401 of controller 204 .
FIG. 6 depicts some salient operations according to the illustrative embodiment of the present invention, in which a first-position limit and a second-position limit are detected.
FIG. 7 depicts controller 700 .
FIGS. 8A and 8B depict conditions that can occur when powering motor 201 on and off, respectively.
FIG. 9 depicts a schematic diagram of the salient components of switching unit 403 of controller 204 , in accordance with the illustrative embodiment of the present invention.
FIGS. 10A and 10B depict conditions that can occur when a limit switch cuts off a winding.
FIG. 11 depicts some salient operations of method 1100 according to the illustrative embodiment of the present invention, in which motorized device 203 is calibrated and utilized.
FIG. 12 depicts the salient sub-operations of task 1101 of method 1100 .
FIG. 13 depicts the salient sub-operations of task 1103 of method 1100 .
DETAILED DESCRIPTION
FIGS. 1A and 1B depicts a picture of motorized system 100 in accordance with the illustrative embodiment of the present invention. Motorized household system 100 comprises motor 101 , AC power source 102 , motorized device 103 , and controller 104 , interrelated as shown. As depicted, motorized device 103 comprises a window blind that is driven, operated, and controlled by motor 101 and controller 104 , and has limits of movement in two directions across one dimension—namely, “up” and “down” across a vertical dimension. It will be clear to those skilled in the art, however, after reading this specification, how to make and use embodiments of the present invention in which a type of motorized appliance, device, or object different from a window blind is driven, operated, and controlled, as well as being governed by limits of movement (e.g., rotational, translational, etc.) in one or more directions across one or more dimensions.
Motor 101 is configured with a double winding and powered by alternating current (AC) line voltage, which is 110 VAC in the United States and 230 VAC in the European Union, for example and without limitation, provided by AC power source 102 . The respective two windings drive upward motion and downward motion in window blind 103 . Motor 101 has built-in limit switches that cut off electrical power when the blind reaches the top or bottom position. When blind 103 connected to motor 101 is raised and reaches the topmost position, as shown in FIG. 1A , the winding that powers the upward movement is cut off. Similarly, when the blind is lowered and reaches the bottommost position, as shown in FIG. 1B , the winding that powers the downward movement is cut off.
The motorized window blind can be controlled remotely via a smartphone or by a smart-home management system. These allow the position of the window blind also to be set at an intermediate position anywhere between being fully opened and fully closed. Accordingly, and as described in detail later, controller 104 is configured to communicate with a controlling application on a smartphone or with a smart-home system that executes the movement of the blinds automatically based on built-in rules, scenes, and presets. Commands are exchanged via a wired or wireless digital connection between the controlling application (in the smartphone or system) and controller 104 . Moving blind 103 to an intermediate position requires controller 104 to track the movement as a proportionate, percentage distance between the topmost and bottommost limit. In doing so, the controller has to know the time it takes for blind 103 to move from the 0% to 100% position and also the time it takes it to move from the 100% to 0% position; this is because the times can differ, in that upward movement usually takes more time than downward movement, owing to gravity.
FIG. 2 a schematic diagram of motorized system 200 in accordance with the illustrative embodiment of the present invention. System 200 comprises motor 201 , AC power source 202 , motorized device 203 , controller 204 , switch 205 , and mobile station 206 , interrelated as shown. Motor 201 , corresponding to motor 101 in FIG. 1 , is configured with a double winding and powered by alternating current (AC) line voltage, which is provided by AC power source 202 in well-known fashion, which corresponds to power source 102 . Motor 201 drives (e.g., moves, rotates, etc.) motorized device 203 , which is mechanically coupled to motor 201 in well-known fashion. Device 203 , corresponding to device 103 , is illustratively a window blind. As those who are skilled in the art will appreciate after reading this specification, however, device 203 can be another type of motorized device or appliance—household or otherwise.
As depicted in FIG. 3 , a first winding W 1 is energized by voltage that is applied to line 211 relative to neutral line 231 , and a second winding W 2 is energized by voltage that is applied to line 212 relative to neutral line 231 . The two windings drive upward motion and downward motion, respectively, in a motorized device 203 . Motor 201 further comprises limit switches, namely LM 1 and LM 2 , which cut off power when the blind reaches the top or bottom position. When a blind that is mechanically coupled to motor 201 via shaft SH is raised and reaches the topmost position, winding W 1 that powers the upward movement is cut off by limit switch LM 1 when LM 1 senses that rotor RO, which is connected to shaft SH, has stopped rotating in a first rotation direction. Similarly, when the blind is lowered and reaches the bottommost position, winding W 2 that powers the downward movement is cut off by limit switch LM 2 when LM 2 senses that rotor RO has stopped rotating in a second rotation direction. Power should never be applied to both winding W 1 and W 2 at the same time.
Returning now to FIG. 2 , controller 204 , corresponding to controller 104 , is a controller module that is configured to perform various functions, including at least some of the tasks described below and in the accompanying figures, including FIGS. 6 and 9-11 . Generally speaking, controller 204 communicates with external devices and systems, such as mobile station 206 or a smart home system, for example and without limitation. Additionally, it controls motor 201 , in part as a result of a calibration process and by relying on stored information as described below. Controller 204 also detects the extreme positions in movements of a driven object, such as motorized window blinds, in order to calibrate the motorized device automatically. Controller 204 is described in detail below and in FIG. 4 .
As those who are skilled in the art will appreciate after reading this specification, controller 204 can be configured to control movement (e.g., rotational, translational, etc.) in one or more directions across one or more dimensions, and to control a different type and/or a different number of movements of motor 201 and/or device 203 than depicted.
Switch 205 is an optional “local” wired momentary switch. When pressed “up,” a contact between line 221 and common line 231 is closed as long as the switch is being depressed, and when pressed “down,” a contact between line 222 and common line 231 are closed. The “up” and “down” inputs are considered soft-switch inputs, as they do not switch the current to motor 201 . Instead, they are binary switch inputs provided to a microcontroller that is part of controller 204 , namely microcontroller unit 401 as described below, wherein the microcontroller decides what actions should be executed. Usually, the actions are “up” and “down” but can also be preset selections or scene selections. Also, the microcontroller can discriminate between “short” and “long” presses. For example and without limitation, a relatively long press (e.g., greater than 10 seconds) of both switches could indicate that an auto-calibration sequence is to be initiated, as described elsewhere in this specification.
Mobile station 206 is a wireless telecommunications terminal that is configured to transmit and/or receive communications wirelessly. It is an apparatus that comprises memory, processing components, telecommunication components, and user interface components (e.g., display, speaker, keyboard, microphone, etc.). Mobile station 206 comprises the hardware and software necessary to be compliant with the protocol standards used in the wireless network or networks in which it operates and to perform or support execution of the processes described below and in the accompanying figures. For example and without limitation, mobile station 206 is capable of:
i. receiving an incoming (i.e., “mobile-terminated”) telephone call or other communication (e.g., application-specific data, SMS text, email, media stream, etc.), ii. transmitting an outgoing (i.e., “mobile-originated”) telephone call or other communication (e.g., application-specific data, SMS text, email, media stream, etc.), iii. controlling and monitoring controller 204 , and/or iv. receiving, transmitting, or otherwise processing one or more signals in support of one or more of capabilities i through iii.
Furthermore, mobile station 206 is illustratively a smartphone with at least packet data capability provided and supported by the network in which it operates and that is configured to execute a software application (e.g., an “app”) for controlling one or more controllers 204 . In some alternative embodiments of the present invention, mobile station 206 can be referred to by a variety of alternative names such as, while not being limited to, a wireless transmit/receive unit (WTRU), a user equipment (UE), a wireless terminal, a cell phone, or a fixed or mobile subscriber unit. In some alternative embodiments of the present invention, mobile station 206 communicates directly with an intermediate controller (not depicted), which in turn is capable of controlling and monitoring controller 204 .
Communication between mobile station 206 and controller 204 is enabled by a wireless network that comprises Bluetooth Low Energy (BLE) network. However, as those who are skilled in the art will appreciate after reading this specification, the wireless network can be based on one or more different types of wireless network technology standards, in addition to or instead of BLE, such as Z-Wave, ZigBee, Wi-Fi, Bluetooth Classic, or Thread, for example and without limitation, in order to enable communication between the mobile station and controller. Furthermore, as those who are skilled in the art will appreciate after reading this specification, mobile station 206 and controller 204 in some embodiments can be connected directly and non-wirelessly to each other, at least for some purposes and/or for some portion of time, such as through Universal Serial Bus (USB), FireWire™, or Thunderbolt™, for example and without limitation.
FIG. 4 depicts a schematic diagram of controller 204 in accordance with the illustrative embodiment of the present invention. Controller 204 comprises microcontroller unit 401 , power supply 204 , and switching unit 403 , as well as voltage measurement detectors VM 1 and VM 2 , driver 415 , direction relay 416 , all of each are interconnected as shown.
Microcontroller unit 401 comprises a programmable microprocessor with program (non-volatile) memory, persistent data (non-volatile) memory, and random access (volatile) memory, along with a communications module. Microcontroller unit (MCU) 401 executes the logic that performs the various procedures as described below and in the accompanying figures. Based on the logic executed, MCU 401 interprets input signals on lines 221 and 222 from respective switch terminals SW 1 and SW 2 within switch 205 , which provides inputs to MCU 401 . In one mode, MCU 401 emulates the switching behavior of SW 1 and SW 2 as if lines 221 and 222 were directly connected to windings W 1 and W 2 , respectively (i.e., driving the windings directly). The SW 1 and SW 2 terminals enable connecting existing motor controller switches, effectively converting an existing “dumb” motor switch into a “smart/connected” motor controller by introducing controller 204 . MCU 401 can sense and execute different set of actions based on how the switches are operated; for example and without limitation, i) a short, single press of a switch can start/stop the motor, and ii) a long (e.g., greater than 5 seconds, etc.) press of a switch or of both switches can initiate the calibration process. The SW 1 and SW 2 terminals are galvanically isolated via optocouplers (omitted for clarity purposes).
Also, based on the logic executed MCU 401 interprets input signals on voltage detector lines 411 and 412 accordingly. As described below, a signal on line 411 can be used to determine movement or stoppage of motor 201 in one direction by the voltage, or change in voltage, induced on winding W 1 and correspondingly reflected on line 411 ; similarly, a signal on line 412 can be used to determine movement or stoppage of the motor in the opposite direction by the voltage, or change in voltage, induced on winding W 2 and correspondingly reflected on line 412 .
Further based on the logic executed, MCU 401 provides output signals on lines 413 and 414 accordingly. MCU 401 provides for communication with mobile station 206 via antenna path 419 . Power to MCU 401 is provided via line 418 .
Power supply 402 converts AC line voltage (or “mains” power) that is provided at line 241 , to a direct-current (DC) voltage suitable for microcontroller unit 401 . Supply 402 provides the DC power to MCU 401 via line 418 . The neutral line in the AC supply corresponds to line 231 . It will be clear to those skilled in the art how to make and use power supply 402 .
Switching unit 403 is part of a driver circuit that is configured to drive motor 201 , controlling motor 201 in a first direction via line 211 and in a second direction via line 212 . Unit 403 is driven by MCU 401 using signals provided via line 414 . Furthermore, unit is configured to switch AC power on line 241 on or off, to relay 416 via line 417 . Related to this, unit 403 features protection against induced voltage, as described below. Switching unit 403 is described below and in FIG. 9 .
Relay 416 is an electromechanical relay that is configured to switch the power signal present on line 417 , to either line 211 or 212 , based on the direction-switching signal present on line 413 and conditioned, if necessary, by driver 415 . In some alternative embodiments of the present invention, relay 416 is a different type of relay than electromechanical.
Voltage measurement detectors VM 1 and VM 2 detect the voltage level present on lines 211 and lines 212 , respectively, in well-known fashion. In particular, when a voltage is induced on winding W 1 , detector VM 1 detects, relative to ground, the voltage induced at winding W 1 and provides an indicium of the value to MCU 401 via line 411 . Similarly, when a voltage is induced on winding W 2 , detector VM 2 detects, relative to ground, the voltage induced at W 2 and provides an indicium of the value to MCU 401 via line 412 . For example and without limitation, the detector circuit comprising detectors VM 1 and VM 2 can be used to detect the upper and lower limits of a motorized window blind, or the extreme positions of a different type of device 203 , and can enable the calibration process described below.
FIG. 5 depicts a block diagram of the salient components of microcontroller unit 401 in accordance with the illustrative embodiment of the present invention. In particular, microcontroller unit (MCU) 401 comprises: processor 501 , memory 502 , network interface module 503 , input/output interfaces 504 and 505 , power distribution bus 506 , and electrical ground 507 , which are interconnected as shown.
Processor 501 is a general-purpose microprocessor that is configured to execute operating system 521 and application software 522 , and to populate, amend, use, and manage database 523 , as described in detail below and in the accompanying figures, including FIGS. 6 and 9-11 . In any event, it will be clear to those skilled in the art how to make and use processor 201 .
Memory 502 is non-transitory and non-volatile computer storage memory technology that is well known in the art (e.g., flash memory, etc.). Memory 502 is configured to store operating system 521 , application software 522 , and database 523 . The operating system is a collection of software that manages, in well-known fashion, MCU 401 's hardware resources and provides common services for computer programs, such as those that constitute the application software. The application software that is executed by processor 501 enables MCU 401 to perform the functions disclosed herein. Database 523 comprises information relating to current position of motorized device 203 , and also the calibrated time intervals of motorized device 203 's movements in various directions (e.g., up, down, etc.).
It will be clear to those having ordinary skill in the art how to make and use alternative embodiments that comprise more than one memory 502 ; or comprise subdivided segments of memory 502 ; or comprise a plurality of memory technologies that collectively store the operating system, application software, and database.
Network interface module 503 comprises a network adapter configured to enable MCU 401 to transmit information to and receive information from a smart home system or a user device, such as mobile station 206 , for example and without limitation. Module 503 communicates wirelessly via Bluetooth Low Energy (BLE) in accordance with the illustrative embodiment of a present invention. In some other embodiments of the present invention, network interface module 503 can communicate via one or more different types of wireless network technology standards, in addition to or instead of BLE, such as Z-Wave, ZigBee, Wi-Fi, Bluetooth Classic, or Thread, for example and without limitation. In a multiple-protocol configuration, a first network adapter can support a first standard (e.g., BLE, etc.), a second network adapter can support a second standard (e.g., WiFi, etc.), and so on, for example and without limitation.
As those who are skilled in the art will appreciate after reading this specification, module 503 can comprise one or more of the elements that are depicted in FIG. 5 as being separate from module 503 , such as processor 501 and/or memory 502 .
In accordance with the illustrative embodiment, MCU 401 uses network interface module 503 in order to telecommunicate wirelessly with external devices. It will be clear to those skilled in the art, however, after reading the present disclosure, how to make use and use various embodiments of the present invention in which MCU 401 communicates via a different type of wireless network (e.g., personal area network, local area network, etc.), or via a wired protocol (e.g., X10, KNX, etc.) over physical media (e.g., cable, wire, etc.) with one or more external devices, either in addition to or instead of the wireless capability provided by module 503 . In any event, it will be clear to those skilled in the art, after reading this specification, how to make and use network interface module 503 .
Input/output (I/O) interfaces 504 and 505 are I/O devices that provide, in well-known fashion, the various characteristics needed in order to receive signals from and to transmit signals to the various devices with which MCU 401 interacts.
Power distribution system 506 provides power from power supply 402 to the various devices that constitute MCU 401 , in well-known fashion. For purposes of clarity, the individual signal lines between bus 506 and their respective devices are not depicted.
Electrical ground system 507 provides an electrical ground for the devices within MCU 401 , as needed, in well-known fashion.
Detection of Limits of Motion—
As explained earlier, a motor of a window blind typically comprises two windings, in which one of the windings, when energized, drives the motor in a first direction of rotation and the other winding drives the motor in a second direction. The motor typically has limit switches that cut off power to the motor when the blind reaches its top or bottom position. Most such motors do not have output terminals to expose signals from the internal limit switches; therefore, motorized systems must rely on something else to determine that a motorized device has reached a limit of movement, such as the blind reaching its topmost or bottommost position. In some techniques in the prior art, a controller connected to the motor measures the current being drawn by the rotating motor and determines the moment when the limit switch opens by detecting when the current flow stops. This measurement of current flow requires a relatively expensive sensing circuit.
FIG. 6 depicts some salient operations of method 600 according to the illustrative embodiment of the present invention, in which a first-position limit (e.g., up-position limit) and a second-position limit (e.g., down-position limit) are detected, not as in the prior art by measuring the change in current flow through a primary winding, defined as the winding that is driving motor 201 , but by measuring the change in voltage in the corresponding secondary winding of the motor. This is based on the observation that applying power to the primary winding of motor 201 results in movement of the motor, which in turn results in an induction of voltage in the secondary winding. As already discussed, a circuit providing the measurement of voltage is described in the previous figures; in particular, voltage measurement detectors VM 1 and VM 2 and MCU 401 in FIG. 4 make up the voltage measurement and control circuitry.
In accordance with the illustrative embodiment of the present invention, the actions depicted in FIG. 6 and the accompanying voltage measurement circuitry in some of the other figures are directed at enabling calibration of a motorized device such as window blinds. However, it will be clear to those skilled in the art after, after reading this specification, how to make and use embodiments of the present invention in which the aforementioned actions and circuitry are applied to other types of systems and/or for other purposes than calibration.
In regard to method 600 , as well as to the methods depicted in the other flowcharts contained herein, it will be clear to those having ordinary skill in the art, after reading the present disclosure, how to make and use alternative embodiments of the disclosed methods wherein the recited operations, sub-operations, and messages are differently sequenced, grouped, or sub-divided—all within the scope of the present invention. Also, it will be further clear to those skilled in the art, after reading the present disclosure, how to make and use alternative embodiments of the disclosed methods wherein at least some of the described operations, sub-operations, and messages are optional, are omitted, or are performed by other elements and/or systems.
At task 601 , motorized system 200 comprising motor 201 , motorized device 203 , and controller 204 is provided and powered on. In accordance with the illustrative embodiment, motorized device 203 comprises a window blind capable of being moved up and down; however, it will be clear to those skilled in the art, after reading this specification, how to use embodiments of the present invention in which motorized device 203 is something other than a window blind.
At task 603 , controller 204 applies a predetermined voltage at the first end of winding W 1 of motor 201 beginning at time t 1 ; that is, voltage is provided via terminal 251 connected to line 211 , wherein the voltage is relative to terminal 253 connected to neutral line 231 . Applying power to winding W 1 results in movement of motor 201 in a first direction (e.g., “up”), which in turn results in the induction of voltage in the opposite winding W 2 . Detector VM 2 is capable of detecting the induced voltage in winding W 2 .
When motor 201 stops rotating in the first direction (i.e., when limit switch LM 1 is opened), the secondary induced voltage drops to zero in winding W 2 . By measuring the secondary voltage drop, controller 204 indirectly senses that the limit switch has been activated. Corresponding to this effect, at task 605 , detector VM 2 of controller 204 detects at time t 2 a decrease in the magnitude of voltage across winding W 2 (i.e., across terminals 252 and 253 connected to lines 212 and 231 , respectively). Controller 204 can detect this decrease even as it is still applying voltage across winding W 1 .
At task 607 , MCU 401 of controller 204 generates and outputs a first signal (e.g., a message, etc.) based on the decrease detected at task 605 . MCU 401 provides a time indication in the first signal based on the elapsed time between t 1 and t 2 . In some embodiments, MCU 401 generates the signal based on the magnitude falling substantially to zero.
In some embodiments, the generating of the first signal is further based on detecting a decrease in magnitude of current across terminals 251 and 253 , which is caused by limit switch LM 1 shutting off power to winding W 1 .
At task 609 , controller 204 stops the application of the voltage at the first end of winding W 1 beginning at time t 3 based on the detecting of the decrease in magnitude of voltage across terminals 252 and 253 . In some embodiments, t 3 is based on the first signal.
At task 611 , controller 204 applies a predetermined voltage at the first end of winding W 2 of motor 201 beginning at time t 4 ; that is, voltage is provided via terminal 252 connected to line 212 , wherein the voltage is relative to terminal 253 connected to neutral line 231 . Applying power to winding W 2 results in movement of motor 201 in a second direction (e.g., “down”, opposite to the first direction, etc.), which in turn results in the induction of voltage in the opposite winding W 1 . Detector VM 1 is capable of detecting the induced voltage in winding W 1 .
When motor 201 stops rotating in the second direction (i.e., when limit switch LM 2 is opened), the secondary induced voltage drops to zero in winding W 1 . By measuring the secondary voltage drop, controller 204 can indirectly sense that the limit switch has been activated. Corresponding to this effect, at task 613 , detector VM 1 of controller 204 detects at time t 5 a decrease in the magnitude of voltage across winding W 1 (i.e., across terminals 251 and 253 connected to lines 211 and 231 , respectively). Controller 204 can detect this decrease even as it is still applying voltage across winding W 2 .
At task 615 , MCU 401 of controller 204 generates and outputs a second signal (e.g., a message, etc.) based on the decrease detected at task 613 . MCU 401 provides a time indication in the second signal based on the elapsed time between t 4 and t 5 . In some embodiments, MCU 401 generates the signal based on the magnitude falling substantially to zero.
In some embodiments, the generating of the second signal is further based on detecting a decrease in magnitude of current across terminals 252 and 253 , which is caused by limit switch LM 2 shutting off power to winding W 2 .
Generally speaking, by measuring the drop in the induced voltage of the secondary winding, controller 204 is able to sense that motor 201 has stopped, which is caused by a limit switch having been activated. Measuring voltage is easier and requires simpler and less expensive circuitry compared to measuring the current flow through the primary winding in order to determine the power draw on that primary winding driving the motor.
In some embodiments of the present invention, controller 201 measures the induced voltage of the secondary winding and measures the applied voltage in the primary winding, and correlates the two measurements with each other. In doing so, controller 204 is able to sense whether motor 201 has stopped by itself, which can be caused by a limit switch having been activated, or has stopped as a result of an intentional action, such as by a user pressing a switch to stop the motor. If the applied voltage is still present, for example, then the motor might have stopped by itself, but if the applied voltage is no longer present, then the motor might have been stopped intentionally.
Protection of the Driver Circuit—
FIG. 7 depicts certain features of an alternative configuration of controller 204 , which alternative configuration is labeled as controller 700 . As with controller 204 , controller 700 is configured to control motor 201 via lines 211 and 212 and is configured to provide AC power provided via line 241 to a particular motor winding via a direction relay, in this configuration labeled as relay 701 . In controller 700 , relay 701 is provided with power via line 702 connected to power relay 703 . Relay 703 is configured to switch the AC power that is provided to the selected winding either on or off.
As discussed earlier, motor 201 comprises built-in limit switches LM 1 and LM 2 . They open the circuit, effectively cutting off power to their respective winding, whenever the limit positions are reached (e.g., up/down, left/right, etc.), depending on the setup of the device driven by the motor.
Powering on the motor is associated with two effects: i) the inertia of rotor RO, and ii) the induction of the winding. When powering on motor 201 , the inertia of rotor RO results in a current peak that exceeds the nominal current by a factor of four to ten times. The current oscillates rapidly because of the induction of the winding, as depicted in FIG. 8A , which is based on a screenshot from an oscilloscope. The figure shows current in the first winding and induced voltage in the second winding.
When motor 201 reaches the upper or lower limit position, the limit switch cuts off the power to the active circuit. At that moment there is an accumulated energy in the motor and winding. This energy generates (induces) an overvoltage condition in both windings W 1 and W 2 . Overvoltage generated in the second winding makes it especially difficult to use two TRIACs (i.e., one on, the other off) in place of direction switching relay 701 . The phenomenon is depicted in FIG. 8B , which is based on a screenshot from an oscilloscope. On a 230 VAC motor, induced voltage has been observed as reaching 1500V. As shown in the figure, cutting off power to the first winding results in a high voltage spike in the second winding. Notably, the “hairy” part of waveform is caused by the vibrating switch contacts that are opening.
FIG. 9 depicts a schematic diagram of the salient components of switching unit 403 , which is intended to address the aforementioned problems, in accordance with the illustrative embodiment of the present invention. Switching unit 403 of controller 204 supports a cascaded relay-TRIAC configuration, wherein TRIAC stands for “triode for alternating current,” in which relay 416 is used to select the direction of motor 201 , as described above, and TRIAC TR 1 is used to switch on or off the AC power provided to relay 416 .
TRIAC TR 1 as depicted comprises an MT 1 terminal (also referred to as a “T1” terminal or an “A1” terminal), an MT 2 terminal (also referred to as a “T2” terminal or an “A2” terminal), and a gate, as are known in the art. In some alternative embodiments, TR 1 is a different type of thyristor or electronic switching device than a TRIAC, which can conduct current in either direction when it is triggered (i.e., turned on). In regard to configuration, TR 1 in some alternative embodiments is flipped in relation to what is depicted in FIG. 9 , such that MT 2 is where MT 1 is depicted, and vice-versa.
Transient-voltage-suppression, or “TVS”, diode D 1 , as is known in the art, has i) a first terminal electrically coupled to the MT 2 terminal of TR 1 and ii) a second terminal. In some embodiments of the present invention, components that are “electrically coupled” are specifically directly and electrically connected. An example of a TVS diode is a Transil™ diode.
TVS diode D 2 has i) a first terminal electrically coupled to the second terminal of diode D 1 and ii) a second terminal electrically coupled to the MT 1 terminal of TR 1 . In some alternative embodiments, a different type of diode or electronic component used to protect electronics from voltage spikes on connected wires can be used in place of TVS diode D 1 and/or D 2 .
Resistor R 1 has i) a first terminal electrically coupled to the second terminal of diode D 1 and the first terminal of the diode D 2 and ii) a second terminal electrically coupled to the gate of TR 1 . The ohmic resistance of resistor R 1 is selected such that TR 1 conducts electrical current between the MT 1 and MT 2 terminals if the predetermined voltage across the diode D 2 is exceeded. In some embodiments of the present invention, resistor R 1 has a value of 1000 ohms.
Opto-triac OPT 1 has i) a light-emitting diode (LED) and ii) a TRIAC that has a) a first terminal electrically coupled to the first terminal of the diode D 1 , b) a second terminal electrically coupled to the second terminal of diode D 1 and the first terminal of the diode D 2 , and c) a gate configured to cause electrical current to be conducted between the first and second terminals of the TRIAC based on light emitted by the LED. Microcontroller unit 401 is electrically coupled to the LED, in this case through resistor R 2 , wherein the microcontroller is configured to switch the OPT 1 TRIAC via the LED.
AC voltage source 202 is electrically coupled to the MT 1 terminal of TR 1 , and relay 416 is electrically coupled to the MT 2 terminal of TR 1 .
A theoretical alternative to the cascaded relay-TRIAC configuration of switching unit 403 would be to use two TRIACs, one on each winding. This two-TRIAC approach, however, is problematic because of the induced voltage on the passive winding that occurs when motor 201 stops, such as when a limit switch opens the active winding (i.e., the winding powering the motor). The induced voltage can pierce the TRIAC connected to the passive winding. This TRIAC cannot be protected with TVS diodes D 1 and D 2 , as this will lead to a closing of the seconding winding circuit, causing motor 201 to immediately start to rotate in the opposite direction because the secondary winding will be powered.
In regard to operation, motor 201 is started by MCU 401 selecting a position of relay 416 according to the intended rotation direction via the appropriate signal being provided on line 413 . After the relay contacts are stable (typically after about 20 milliseconds), voltage for driving opto-triac OPT 1 is applied at line 414 . Opto-triac OPT 1 starts conducting current after the AC voltage crosses zero and causes TRIAC TR 1 to start conducting current. As a result, the power is applied to the motor winding without generating any sparks on relay contacts. In some embodiments of the present invention, the inrush current that TRIAC TR 1 can sustain must be enough to accommodate the inrush current of the stationary motor winding.
Motor 201 is now rotating at this point, and there are two ways to stop it:
i. turning off the voltage driving opto-triac OPT 1 that is being applied at line 414 , and ii. activating a limit switch by the motor reaching the corresponding upper or lower limit position.
In the first case, TRIAC TR 1 stops conducting current when the line AC voltage (i.e., between MT 1 and MT 2 ) reaches zero. No overvoltage condition occurs in this case.
In the second case, the limit switch cuts off the circuit asynchronously to the line AC. When the contacts of the limit switch are opening, there are many high frequency, high voltage oscillations in both windings when no suppression circuit is present, as depicted in FIG. 10A . In this case, the voltage can reach upwards of 1500V. The oscillating high voltage forms an electric arc between the opening contacts of the limit switch and hits TRIAC TR 1 . The TRIAC is too slow to suppress the high voltage. The current conducted by the TRIAC can rise at a rate of several amps per microsecond (uS). If the high voltage oscillations rise at a higher rate than about 100V/uS, which they can do, the TRIAC will not conduct the resulting current fast enough. This would lead to piercing the TRIAC.
To prevent the TRIAC from being pierced, the two TVS diodes, which conduct current much faster than a TRIAC can, serve to suppress the fast-rising, high voltage. In the illustrative embodiment, when the voltage across MT 1 and MT 2 terminals exceeds 420V, TVS diodes D 1 and D 2 start conducting the current, thereby preventing any further rise of the voltage. The diodes, however, cannot suppress the entire energy accumulated in the motor—their junctions would evaporate if called upon to do so. To prevent this, a second-stage circuit (sometimes referred to as a “crowbar”) is implemented in switching unit 403 , in which resistor R 1 powers TRIAC TR 1 's gate, the TRIAC starts conducting the current and takes over the load from diodes D 1 and D 2 , protecting the diodes from overheating. FIG. 10B reflects the behavior of switching unit 403 in providing the protection described above. In this case, the voltage does not exceed 10V.
Consistent with its configuration and operation as described above, controller 204 , comprising direction-switching relay 416 and switching unit 403 , is intended to provide at least one or more of the following features:
i. full control of bi-directional motors up to at least 500 W/230 VAC. ii. protection against powering both windings W 1 and W 2 simultaneously. iii. electronic, spark-free powering on and off of motor 201 . iv. dual-phase suppression of overvoltage when motor 201 is stopped by a limit switch. v. reduced size of the circuit, in that there is only a single mechanical relay 416 rather than two mechanical relays. vi. enhanced durability. vii. no need for a traditional RC overvoltage suppressor.
Automatic Calibration—
FIG. 11 depicts some salient operations of method 1100 according to the illustrative embodiment of the present invention, in which motorized device 203 is calibrated and utilized. A smartphone application executed by mobile station 206 is configured to communicate with the controller 204 , either directly with the controller or indirectly through an intermediary smart-home-control system. Having such an application interacting with controller 204 enables a guided, automatic calibration process.
At task 1101 , controller 204 calibrates device 203 in accordance with the method described below and in FIG. 12 . Calibration refers to ensuring that the motorized device is at the position where the user believes it to be.
At task 1103 , controller 204 utilizes device 203 in accordance with the method described below and in FIG. 13 . Utilization refers to routine usage of the motorized device by the user.
As those who are skilled in the art will appreciate after reading this specification, either or both of tasks 1101 and 1103 can be repeated in any combination of repetitions.
FIG. 12 depicts the salient sub-operations of task 1101 . At task 1201 , controller 204 receives a command from mobile station 206 to calibrate motorized device 203 , which is mechanically coupled to shaft SH of motor 201 .
Based on receiving the command, at task 1203 controller 204 actuates motor 201 in order to move motorized device 203 to a first position (e.g., window blinds in the full down position, etc.).
Based on receiving the command, at task 1205 controller 204 actuates motor 201 by providing voltage at a first winding of the motor. The actuating is such that the shaft rotates in a first direction moving motorized device 203 from the first position toward a second position (e.g., window blinds in the full up position, etc.).
At task 1207 , controller 204 detects whether device 203 has reached the second position. Only if it has does controller 204 proceed to task 1209 . In some embodiments of the present invention, controller 204 detects that the device 203 has reached the second position by measuring voltage on the second winding, as described above and in FIG. 6 .
At task 1209 , controller 204 determines and stores the elapsed time in moving from the first position to the second position. In addition, controller 204 stores the second position as the current position of device 203 .
At task 1211 , controller 204 actuates motor 201 by providing voltage at a second winding of the motor. The actuating is such that the shaft rotates in a second direction moving motorized device 203 from the second position (e.g., up position, etc.) toward the first position (e.g., down position, etc.).
At task 1213 , controller 204 detects whether device 203 has reached the first position. Only if it has does controller 204 proceed to task 1215 . In some embodiments of the present invention, controller 204 detects that the device 203 has reached the first position by measuring voltage on the first winding, as described above and in FIG. 6 .
At task 1215 , controller 204 determines and stores the elapsed time in moving from the second position to the first position. In addition, controller 204 stores the first position as the current position of device 203 .
At task 1217 , controller 204 transmits a message based on device 203 having reached the first position as detected at task 1213 . In some embodiments of the present invention, controller 204 transmits one or more additional status messages (e.g., when device 203 was brought to the first position initially at task 1203 , when device 203 reached the second position as detected at task 1207 , etc.).
Control of execution then proceeds to task 1103 .
FIG. 13 depicts the salient sub-operations of task 1103 . At task 1301 , controller 204 receives a command to move device 203 to a target position (e.g., down from the top by 60%, etc.).
Based on receiving the command at task 1301 , at task 1303 controller 204 determines whether device 203 is to move toward the first position or the second position, based on comparing the stored current position with the target position that is either received or derived from the received command.
At task 1305 , controller 204 calculates the amount of time needed for device 203 to move to the target position, based on a selection of i) the stored elapsed-time-toward-first-position of ii) the stored elapsed-time-toward-second-position, wherein the selection is based on the required direction of movement that was determined at task 1303 . The amount of time is also based on the current position.
At task 1307 , controller 204 actuates motor 201 by providing voltage at a particular winding of the motor. The winding is selected based on the required direction of movement and is energized based on the amount of time calculated at task 1305 to get to the target position.
At task 1309 , controller 204 transmits a message based on device 203 having reached the target position. In some embodiments of the present invention, controller 204 transmits one or more additional status messages (e.g., a progress indication, etc.).
It is to be understood that the disclosure teaches just one example of the illustrative embodiment and that many variations of the invention can easily be devised by those skilled in the art after reading this disclosure and that the scope of the present invention is to be determined by the following claims. | A motorized system that allows for calibration by a user, and that features circuit protection and detection of motor stoppage. A motorized window-blind system is an example of such a system and is disclosed herein. In particular, a circuit is featured that comprises a TRIAC, or “triode for alternating current,” and TVS diodes, or “transient-voltage-suppression diodes,” providing voltage protection to various types of motor-related electronic components. A controller is disclosed that features measurement of voltage that is induced on a secondary winding of a motor, in order to detect certain events that occur during the operation of the motor. A calibration method is also disclosed that can account for one or both of the protection circuit and event-detecting controller. The calibration method accounts for human interaction and, in doing so, is intended toward making a calibration process of a motorized household system less prone to human error. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 61/606,580, filed Mar. 5, 2012.
BACKGROUND
Light emitting diodes (LEDs) generate light in zones so small (a few mm across) that it is a perennial challenge to spread their flux uniformly over a large target zone, especially one that is much wider than its distance from the LED. So-called short-throw lighting, of close targets, is the polar opposite of spot lighting, which aims at distant targets. Just as LEDs by themselves cannot produce a spotlight beam, and so need collimating lenses, they are equally unsuitable for wide-angle illumination as well, and so need illumination lenses to do the job.
A prime example of short throw lighting is the optical lens for the back light unit (BLU) for a direct-view liquid crystal display (LCD) TVs. Here the overall thickness of the BLU is usually 26 mm or less and the inter-distance between LEDs is about 200 mm. Prior art for LCD backlighting consisted of fluorescent tubes arrayed around the edge of a transparent waveguide, that inject their light into the waveguide, which performs the actual backlighting by uniform ejection. While fluorescent tubes are necessarily on the backlight perimeter due to their thickness, light-emitting diodes are so much smaller that they can be placed directly behind the LCD display, (so called “direct-view backlight”), but their punctuate nature makes uniformity more difficult, prompting a wide range of prior art over the last twenty years. Not all of this art, however, was suitable for ultra-thin displays.
Another striking application with nearly as restrictive an aspect ratio is that of reach-in refrigerator cabinets. Commercial refrigerator cabinets for retail trade commonly have glass doors with lighting means installed behind the door hinging posts, which in the trade are called mullions. Until recent times, tubular fluorescent lamps have been the only means of shelf lighting, in spite of how cold conditions negatively affect their luminosity and lifetime. Also, fluorescent lamps produce a very non-uniform lighting pattern on the cabinet shelves. Light-emitting diodes, however, are favored by cold conditions and are much smaller than fluorescent tubes, which allow for illumination lenses to be employed to provide a much more uniform pattern than fluorescent tubes ever could. Because fluorescent tubes radiate in all directions instead of just upon the shelves, much of their light is wasted. With the proper illumination lenses, however, LEDs can be much more efficient, allowing lower power levels than fluorescent tubes, in spite of the latter's good efficacy.
The prior art of LED illumination lenses can be classified into three groups, according to how many LEDs are used:
(1) Extruded linear lenses with a line of small closely spaced LEDs, particularly U.S. Pat. Nos. 7,273,299 and 7,731,395, both by these Inventors, as well as References therein. (2) A line of a dozen or more circularly symmetric illumination lenses, such as those commercially available from the Efficient Light Corporation. (3) A line of a half-dozen (or fewer) free-form illumination lenses with rectangular patterns, such as U.S. Pat. No. 7,674,019 by these Inventors.
The first two approaches necessarily require many LEDs in order to achieve reasonable uniformity, but recent trends in LEDs have produced such high luminosity that fewer LEDs are needed, allowing significant power savings. This is the advantage of the last approach, but free-form lenses generating rectangular patterns have proved difficult to produce, via injection molding, with sufficient figural accuracy for their overlaps to be caustic-free. (Caustics are conspicuous small regions of elevated illuminance.)
What is needed instead is a circularly symmetric illumination lens that can be used in small numbers (such as five or six per mullion) and still attain uniformity, because the individual patterns are such that those few will add up to caustic-free uniformity. The objective of this Invention is to provide a lens with a circular illumination pattern that multiples of which will add up to uniformity across a rectangle. It is a further objective to attain a smaller lens size than the above mentioned approaches, leading to device compactness that results in lower manufacturing cost. The smaller lens size can be achieved by a specific tailoring of its individual illumination pattern. This pattern is an optimal annulus with a specific fall-off that enables the twelve patterns to add up to uniformity between the two illuminating mullions upon which each row of six illuminators are mounted. This fall-off at the most oblique directions is important, because this is what determines overall lens size. The alternative approaches are: (1) Each mullion illuminates 100% to mid-shelf and zero beyond, which leads to the aforementioned caustics; (2) Each mullion contributes 50% at the mid-point, falling off beyond it. The latter is the approach of this Invention, and has proven highly successful.
The prior art is even more challenged, moreover, when fewer LEDs are needed due to ongoing year-over-year improvements in LED flux output. After all, backlight thickness is actually relative to the inter-LED spacing, not to the overall width of the entire backlight. For example, in a 1″ thick LCD backlight with 4″ spacing between LEDs, the lens task is proportionally similar to the abovementioned refrigerator cabinet. Because of the smaller size of an LCD as compared to a 2.5 by 5 foot refrigerator door, lower-power LEDs with smaller emission area will be used, typically a Top-LED configuration with no dome-like silicone lens.
Regarding the prior art patents which have taught non-specific design methods for addressing this problem are: US 2006/0138437, U.S. Pat. No. 7,348,723, U.S. Pat. No. 7,445,370, U.S. Pat. Nos. 7,621,657 and 7,798,679 by Kokubo et al. shows the same cross-sectional lens profile as in FIG. 15A of U.S. Pat. No. 7,618,162 by Parkyn and Pelka, while failing to reference it. U.S. Pat. No. 7,798,679 furthermore contains only generically vague descriptions of that lens profile, and worse yet has no specific method of distinguishing the vast number of significantly different shapes fitting its vague verbiage, its many repetitively generic paragraphs notwithstanding. Experience has shown that illumination lenses are unforgiving of small shape errors, such as result from unskilled injection molding or subtle design flaws. Very small changes in local slope of a lens can result in highly visible illumination artifacts sufficient to ruin an attempt at a product. Therefore such generic descriptions are insufficient for practical use, because even the most erroneous and ill-performing lens fulfills them just as well as an accurate, high-performing lens. Thus U.S. Pat. No. 7,798,679 does not pertain to the preferred embodiments disclosed herein, because it never provides the specific, distinguishing shape-specifications whose precise details are so necessary for modern optical manufacturing.
SUMMARY
Commercial refrigerator display cabinets for retail sales have a range of distances from mullion to the front of the shelves, commonly from 3″ to 8″, with the smaller spacings becoming more prevalent as store owners seek to cram more and more product into their reach-in refrigerator cabinets. Fluorescent tubes have great difficulty with these tighter spacings, leading to an acceleration in the acceptance of LED lighting technology. Even though fluorescent tubes have efficacy comparable to current LEDs, their large size and omnidirectional emission hamper their efficiency, making it difficult to adequately illuminate the mid-shelf region. Early reach-in refrigerator LED illuminators utilized a large number of low-flux LEDs, but continuing advances in luminosity enable far fewer LEDs to be used to produce the same illuminance. This places a premium on having illumination lenses that when arrayed will sum up to uniformity while also having the smallest possible size relative to the size of the LED.
Disclosed herein are preferred embodiments that generate wide-angle illumination patterns suitable for short-throw lighting. Also disclosed is a general design method for generating their surface profiles, one based on nonimaging optics, specifically a new branch thereof, photometric nonimaging optics. This field applies the foundational nonimaging-optics idea of etendue in a new way, to analyze illumination patterns and classify them according to the difficulty of generating them, with difficulty defined as the minimum size lens required for a given size of the light source, in this case, the LED.
OBJECTIVES
It is the first objective to disclose numerically-specific lens configurations that in arrays will provide uniform illumination for a close planar target, especially in retail refrigeration displays and in thinnest-possible direct-view LCD backlights.
It is the second objective to provide compensation for the illumination-pattern distortions caused by volume scattering and scattering due to Fresnel reflections, which together act as an additional, undiscriminating secondary light source.
On fulfillment of the inventor's duty to go beyond superficial description, it is the third objective to disclose fully the design methods that generated the preferred embodiments disclosed herein, such that those skilled in the art of illumination optics could design further preferred embodiments for other illumination applications, in furtherance of the ultimate objective of the patent system that being to expand public knowledge.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and advantages will be apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
FIG. 1 shows how a rectangular door is illuminated by circular patterns.
FIG. 2 shows a graph of an individual illumination pattern.
FIG. 3 shows an end view of the door of FIG. 1 , with slant angles.
FIG. 4 shows a graph of required source magnification.
FIG. 5 shows a cross-section of an illumination lens and LED.
FIG. 6A-6F show source-image rays from across the target.
FIG. 7 shows how a rectangular door is illuminated by only 4 LEDs.
FIG. 8 shows a cross-section of a further illumination lens and LED.
FIG. 9 illustrates a mathematical description of volume scattering.
FIG. 10 is a graph of illumination patterns.
FIG. 11 sets up a 2D source-image method of profile generation.
FIG. 12 shows said method of profile generation.
FIGS. 13A and 13B show the 3D source-image method of profile generation.
FIG. 14 shows a plano-convex lens-center, with defining rays.
FIG. 15 shows a concave-concave lens-center, with defining rays.
FIG. 16 shows a concave-plano lens-center, with defining rays.
FIG. 17 shows the complete lens made from the lens-center of FIG. 14 .
FIG. 18 shows the complete lens made from the lens-center of FIG. 15 .
FIG. 19 shows the complete lens made from the lens-center of FIG. 16 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description of the invention and accompanying drawings, which set forth illustrative embodiments in which principles of the invention are utilized.
FIG. 1 shows rectangular outline 10 representing a typical refrigerator door that is 30″ wide and 60″ high, with other doors, not shown, to either side. Dashed rectangles 11 denote the mullions behind which the shelf lighting is mounted, typically at 3-6″ from the front of the illuminated shelves. This is much closer than the distance to the shelf center, denoted by centerline 12 . There are twelve illuminators 31 (six on either side), four of which are denoted by small circles 1 . Each illuminator 31 produces an illuminated circle with its peak on a ring denoted by solid circles 2 and its edge on dotted circles 3 . Here the circles 2 have radius of a quarter of the shelf width, or halfway to centerline 12 . The circles 3 , where illuminance has fallen to zero, are sized to meet the circles 2 from the opposite mullion.
FIG. 2 shows graph 20 with abscissa 21 that is horizontally scaled the same as FIG. 1 above it. Ordinate 22 is scaled from 0 to 1, denoting the ideal illuminance I(x), as graphed by curve 23 , generated on the shelves by an illuminator 31 under the mullion. This illumination function is relative to the maximum on circle 2 , which has radius x M . It falls off to zero at radius x E . This gradually falling illuminance is paired with the gradually ascending one of the illuminator 31 on the opposite side of the door, so the two patterns add up to constant illuminance along the line 4 of FIG. 1 .
An actual injection-molded plastic lens will exhibit volume scattering within its material, making the lens itself an emitter rather than a transmitter. This volume scattered light will be strongest just over the lens. The central dip in the pattern 23 , shown in FIG. 2 to be at the ¾ level, compensates for this extra volume-scattered light, so that the total pattern (direct plus scattered) is flat within circle 2 . This effect becomes more pronounced with the larger lenses discussed below.
Another advantage of this type of gradually falling-off pattern is that any point on centerline 12 is lit by several illuminators 31 on each mullion, assuring good uniformity. The dotted curve 24 shows the illumination pattern of an LED alone. It is obviously incapable of adding up to satisfactory illumination, let alone uniform, hence the need for an illumination lens 51 to spread this light out properly.
FIG. 3 shows an end view of shelf-front rectangle 30 identical to that of FIG. 1 . Illuminators 31 are located as shown by small rectangles 31 . This addresses the difficulty of lighting from so close to the shelf, in this case at a distance of z T =4″. FIG. 3 shows the distances x m =15″ and x E =22.5″, respectively, to centerline 33 and edge-line 34 , at which the pattern of illuminator 31 has reached zero illuminance. These distances correspond to off-axis angles from the normal given by
γ m =tan −1 ( x m /z T )=tan −1 (15/4)=75° γ E =tan −1 ( x E /z T )=tan −1 (22.5/4)=80°
These large slant-angles drive the lens design, requiring considerable lateral magnification of the source by the lens. At low slant-angles, in contrast, the lens must demagnify.
This concept of magnification and demagnification can be made more explicit via etendue considerations. The source-etendue is that of a chip of area A S =2.1 mm 2 , immersed in a dome of refractive index n=1.45:
E S =πn 2 A S sin 2 θ=14 mm 2
Here θ is 90° for a Lambertian source of which an LED is a very good approximation°.
An illumination lens 51 basically redistributes this etendue over the target, which is much larger than the chip. In the case of the illumination pattern in FIG. 2 , the target etendue relates to the area A T of the 45″ illumination circle of FIG. 1 , as weighted by the relative illumination function 23 of FIG. 2 . This simple model of an actual illumination pattern has a central dip to illuminance I 0 , a rise to unity at x=x M , and a linear falloff to zero at x=x E . This is mathematically expressed as
I ( x )= I 0 +x (1 −I 0 )/ x M x≦x M
I ( x )=( x E −x )/( x E −x M ) x M ≦x≦x E
Then the target etendue is given by an easily solved integral:
E T = π sin 2 θ T ∫ 0 x e 2 π x I ( x ) ⅆ x = 2 π 2 sin 2 θ T ( [ I 0 x 2 2 + ( 1 - I 0 ) x 3 3 x M ] 0 x M + [ x E 2 ( x E - x M ) x 2 - x 3 3 ( x E - x M ) ] x M x E ) E T = sin 2 θ T 1.47 square meters
Here θ T is the half angle of a narrow-angle collimated beam with the same etendue as the source, so that
sin 2 θ T ˜1 E− 5 θ T =±0.18°
At the center of the lens this is reduced by ¾, to ±0.13°. This can be contrasted with the angular subtense of the source alone, as seen from directly above it on the shelf, at distance z T as shown in FIG. 3 :
tan 2 θ S =n 2 A C /4 z T 2 θ S =±0.61°
Thus the central demagnification of the lens needs to be 1:4.5, dictating that the central part of the lens be concave, in order to act as an expander with negative focal length. This can be attained on a continuum of concavity bounded by a flat-topped outer surface with a highly curved inside surface or a flat-topped inner surface with the outer surface highly curved. That of FIG. 5 lies between these extremes.
As shown in FIG. 3 , a high slant angle γ means that to achieve uniform illumination the source image made by the lens must be correspondingly larger than for normal incidence, by a factor of 1/cos γ. The source itself will be foreshortened by a slant factor of cos γ, as well as looking smaller and smaller by being viewed from farther away, by a further factor of cos 2 γ. Thus the required lens magnification is
M ( γ ) = 1 4.5 cos 4 γ
Note that magnification rises from ¼ on-axis to unity at an off-axis angle given by
γ
(
M
)
=
cos
-
1
1
4.5
M
4
γ
(
1
)
=
47
°
These angles dilute the illuminance by a cosine-cubed factor, so that the farther out light must be thrown, the more intense must be the lens output. Considering that the LED source has a cosine fall-off of its own, the total source magnification required is the well-known cos −4 factor, amounting to 223 at 75° 1100 at 80° respectively. Here lies the advantage of the fall-off in the illumination pattern of FIG. 2 , since these deleterious factors are reduced accordingly.
FIG. 4 shows graph 40 with abscissa 41 running from 0 to 80° in off-axis angle γ and ordinate 42 showing the source magnification M(γ) required for uniform illumination. Unit magnification is defined as a source image the same size as if there were no lens. What this magnification means is that the illumination lens 51 of the present invention must produce an image of the glowing source, as seen from the shelf, that is much bigger than the Lambertian LED source without any lens. For uniformly illuminating a 4″ shelf-distance, curve 43 shows that the required magnification peaks at 77.5°, while lower curve 44 is for the much easier case of a 6″ shelf distance, peaking at 71°. This required image-size distribution is the rationale for the configuration of the present invention.
FIG. 5 is a cross-section of illuminator 31 , comprising illumination lens 51 , bounded by an upper surface 46 comprising a central spherical dimple with arc 52 as its profile and a surrounding toroid with elliptical arc 53 as its profile, and also bounded by a lower surface 48 comprising a central cavity 54 with bell-shaped profile 54 and surrounding it an optically inactive cone 55 joining the upper surface 46 , with straight-line profile and pegs 56 going into circuit board 57 . Illuminator 31 further comprises LED package 58 with emissive chip 58 C immersed in transparent hemispheric dome 58 D. The term ‘toroid’ distinguishes from the conventional term ‘torus’, which solely covers the case of zero tilt angle. The highly oblique lighting setup of refrigerator-cabinet shelf-fronts involves tilting the torus so that the lensing effect of the elliptical arc 53 points toward the center of the shelf.
Arc 52 of FIG. 5 extends to tilt angle τ, which in this case is 17°, its importance being that it is the tilt angle of major axis 53 A of elliptical arc 53 . Its minor axis 53 B lines up with the radius at the edge of arc 52 , ensuring profile-alignment with equal surface tangency. There are three free parameters which define a particular outer surface of illumination lens 51 , as intended for different shelf distances. The first is the radius of arc 52 , which controls the amount of de-magnification by the central portion of illumination lens 51 . The second is the tilt angle τ, which defines the orientation of elliptical arc 53 , namely towards the shelf center of FIG. 1 . The third free parameter of the upper surface 46 is the ratio of the radius to the elliptical arc 53 at major axis 53 A to the radius to the elliptical arc 53 at minor axis 53 B, in this case 1.3:1, defining the above-discussed source magnification. Ray-fan 59 comprises central rays (i.e., originating from the center of chip 58 C) at 2° intervals of off-axis angle. The central ten rays designated by dotted arc 59 C, outbound from the centerline or central axis 59 , illustrate the diverging character of the center of lens 51 , which provide the central demagnification required for uniform illumination. The remaining rays are all sent at steep angles to the horizontal, providing the lateral source magnification of FIG. 4 .
The central cavity 54 surrounding LED 58 has bell-shaped profile 54 defined by the standard aspheric formula for a parabola (i.e., conic constant of −1) with vertex at z v , vertex radius of curvature r c , 4 th -order coefficient d and 6 th -order coefficient e:
z ( x )= z v +x/r c +dx 4 +ex 6
In order for profile 54 to arc downward rather than upward, the radius of curvature r c is negative. The aspheric coefficients provide an upward curl 49 at the bottom of the bell, to help with cutting off the illumination pattern. The particular preferred embodiment of FIG. 5 , with a cavity entrance-diameter set at 6.45 mm, is defined by:
z v =6 mm r c =−1.69 mm d=− 0.05215 e= 0.003034
This profile only needs minor modification to be suitable for preferred embodiments illuminating other shelf distances.
FIG. 6A through 6F shows illumination lens 51 and LED chip 61 . In FIG. 6A , rays 62 come from points on the shelf at the indicated x coordinates of 0, 2″, and 4″ laterally from the lens. Each bundle is just wide enough that its rays end at the edges of chip 61 , which is the definition of a source image. Each bundle is narrower than chip 61 would appear by itself, in accordance with the previously discussed demagnification. The central portion of lens 60 that is traversed by rays 62 can be seen to be a concave, diverging lens, as previously mentioned.
FIG. 6B shows ray bundle 63 proceeding from the distance x M to the maximum of the illumination pattern in FIG. 2 . It is twice the width of those in FIG. 6A .
FIG. 6C shows ray bundle 64 proceeding from the distance x m to the middle of the shelf, as shown in FIG. 2 .
FIG. 6D shows ray bundle 65 proceeding from beyond mid shelf, at 18″.
FIG. 6E shows ray bundle 66 proceeding from beyond mid shelf, at 20″, nearly filling the lens. This is the maximum source magnification this sized lens can handle.
FIG. 6F shows ray bundle 67 proceeding from the edge of the illumination pattern, at x E =22″. Note that these rays miss chip 61 , indicating that there will be no light falling there, which is required by the pattern cutoff.
The progression of FIG. 6A through 6F is the basis for the numerical generation of the upper and lower surface profiles of the lens, starting at the center and working outwards, as will be disclosed below. The results of this method can sometimes be closely approximated by the geometry of FIG. 5 .
The illumination lens 51 of FIG. 5 has elliptical and aspheric-parabolic surfaces with shapes that are exactly replicable by anyone skilled in the art. In the illumination pattern of FIG. 2 , the central depression to ¾ the maximum value was empirically found to work with the lens array of FIG. 1 , with six lenses on each side. This lens is the first commercially available design enabling only six LEDs to be used, rather than the dozen or more of the prior art. More recently, however, even higher-power LEDs have become available that only require two per door, as FIG. 7 illustrates.
FIG. 7 shows rectangular outline 70 representing a typical refrigerator door that is 30″ wide and 60″ high, with other doors, not shown, to either side. Dashed rectangles 71 denote the mullions behind which the shelf lighting is mounted, typically at 3-6″ from the front of the illuminated shelves. This is much closer than the distance to the shelf center, denoted by centerline 72 . There are four illuminators 31 (two on either side), denoted by small circles 73 . Each illuminator 31 produces an illuminated circle with its peak on a ring denoted by solid circles 74 and its edge on dotted circles 75 . Here the circles 74 have radius of about a fifth of the shelf width, or a third the way to centerline 72 . The circles 75 , where illuminance has fallen to zero, are sized to reach nearly all the way across the shelf. As in FIG. 1 , each pattern has the value ½ at centerline 72 , so two lenses add to unity. Also, at shelf center-point 76 the four patterns overlap, so at this distance each pattern must have the value ¼, and thus add to unity. This same configuration is applicable for LCD backlights comprising square-arrayed LEDs, merely on a smaller scale. This arrangement of precisely configured illumination lenses 51 is capable of generating uniformity satisfactory for LCD backlights.
The LEDs used in the arrangement of FIG. 7 must be three times as powerful as those used for FIG. 1 . This greater flux has unwanted consequences of triply enhanced scattered light, strengthened even more by the greater size of the lenses used for FIG. 7 versus the smaller ones which would suffice for FIG. 1 . The illumination pattern of FIG. 2 has a central dip in order to compensate for the close spacing of the lenses. When scattering is significant, however, the scattered light can be strong enough to provide all the illumination near the lens. The upshot is that the illumination pattern shown in FIG. 2 would have nearly zero intensity on-axis. The resultant lens has a previously unseen feature: either or both surfaces have a central cusp 82 that leaves no direct light on the axis, resulting in a dark center for the pattern, in order to compensate for the scattered light.
FIG. 8 is a cross-section of illuminator 31 , comprising circularly symmetric illumination lens 51 , bounded by an upper surface comprising a central cusp 82 formed by a surrounding toroid with tailored arc 83 as its profile. Lens 81 is also bounded by a lower surface comprising a central cavity 54 with tailored profile 84 preferably peaking at its tip, and surrounding it an optically inactive cone 55 joining the upper surface, with straight-line profile 85 and pegs 56 going into circuit board 87 . Illuminator 31 further comprises centrally located LED package 88 with emissive chip 88 C immersed in transparent hemispheric dome 88 D.
The optically active profiles 83 and 84 of FIG. 8 are said to be tailored due to the specific numerical method of generating it from an illumination pattern analogous to that of FIG. 2 , but with little or no on-axis output. The reason for this is, as aforementioned, to compensate for real-world scattering from the lens. The profiles 83 and 84 only control light propagating directly from chip 83 C, through dome 83 D, and thence refracted to a final direction that ensures attainment of the required illumination pattern. This direct pattern will be added to the scattering pattern of indirect light, which thus needs to be determined first.
FIG. 9 shows illumination lens 51 , identical to lens 81 of FIG. 8 , with other items thereof omitted for clarity. From LED chip 98 C issues ray bundle 92 , comprising a left ray (dash-dot line), a central ray (solid line), and a right ray (dashed line), issuing respectively from the left edge, center, and right edge of LED chip 98 C. Anywhere within lens 91 , these rays define the apparent size of chip 98 C and thus how much light is passing through a particular point. Any light scattered from such a point will be a fixed fraction of that propagating light. The closer to the LED the more light is present at any point, and the greater the amount scattered. This scattering gives the lens its own glow, separate from the brightness of the LED itself when directly viewed.
Strictly speaking, scattering does not take place at a point but within a small test volume, shown as infinitesimal cube 93 in FIG. 9 , magnified for clarity. It is oriented along the propagation direction of ray bundle 92 . It has cross-section 93 A of area dA and propagation length dl, such that its volume is simply dV=dl dA. Within cube 93 can be seen the left, central, and right rays of bundle 92 , now switched sides. The right and left rays define solid angle Ω, indicating the apparent angular size of LED chip 98 C as seen from cube 93 within lens 91 . The greater this solid angle the more light will be going through cube 93 . LED chip 98 C has luminance L, specified in millions of candela per square meter. This is reduced when ray bundle 92 goes into lens 91 , due to less-than-unity transmittance τ caused by Fresnel reflections. Going into cube 93 the ray bundle 92 has intensity I given simply by I=τ L dA. The total flux F passing through cube 93 is then given, simply again, by F=IΩ.
Volume scattering removes a fixed fraction of this intensity I per unit length of propagation, similar to absorption. Both are described by Beer's law:
I ( l )= I (0) e −κl
Here I(0) is the original intensity and I(l) is what remains after propagation by a distance l, while scattering coefficient κ has the dimension of inverse length. It can easily be determined by measuring the loss in chip luminance as seen through the lens along the path l of FIG. 9 .
Returning to cube 93 of FIG. 9 , the ingoing intensity I is reduced by the small amount dI=e −κdl . This results in a flux decrement dF=dIΩ that is subtracted from F. Then the emission per unit volume is dF/dV. Integrating this over the entire optically active volume of lens 91 gives the total scattered light. FIG. 9 further shows observer 94 gazing along line of sight 95 , along which direct rays 97 give rise to scattering points 96 , summing into a lens glow that acts as a secondary light source surrounding the LED.
These scattering phenomena are usually looked upon as disadvantageously parasitic, acting only to detract from optical performance. There is a new aspect to this, however, where some volume scattering would be beneficial. It arises in the subtle failings of current high-brightness LEDs, namely that of not delivering the same color in all directions. More specifically, many commercially available LEDs with multi-hundreds of lumens output, look much yellower when seen laterally than face-on. This is because of the longer path through the phosphor taken by light from the blue chip.
Thick phosphors have uniform whiteness, or color temperature, in all directions, but they reduce luminance due to the white light being emitted from a much bigger area than that of the blue chip. Conformal coatings, however, are thin precisely in order to avoid enlarging the emitter, but they will therefore scatter light much less than a thick phosphor and therefore do much less color mixing. As a result, lateral light is much yellower (2000 degrees color temp) and the face-on light much bluer (7000 degrees) than the mean of all directions. As a result of this unfortunate side-effect of higher lumen output, the lenses disclosed herein will exhibit distinct yellowing of the lateral illumination, and a distinct bluing of the vertical illumination.
The remedy for this inherent color defect is to use a small quantity of blue dye in the lens material. Since the yellow light goes through the thickest part of the lens, the dye will automatically have its strongest action precisely for the yellowest of the LEDs rays, those with larger slant angles. The dye embedded in the injection-molding material should have an absorption spectrum that only absorbs wavelengths longer than about 500 nm, the typical spectral crossover between the blue LED and the yellow phosphor. The exact concentration will be inversely proportional to lens size as well as to the absorption strength of the specific dye utilized.
A further form of scattering arises from Fresnel reflections, aforementioned as reducing the luminance of rays as they are being refracted. FIG. 9 further shows first Fresnel-reflected ray 92 F 1 coming off the inside surface of lens 91 , then proceeding into the lens to be doubly reflected out of the lens 92 F 1 and onto the printed circuit board. This ray has strength of (1−τ) relative to the original ray 92 , where tau is the coefficient of transmission at the particular point where the ray impinges upon the exit face. Of similar strength is the other Fresnel-reflected ray, 92 F 2 , which proceeds from the outer surface to the bottom of the lens. These two rays are illustrative of the general problem of stray light going where it isn't wanted. Unlike the volume scattering at points 96 , these Fresnel-reflected rays can travel afar to produce very displeasing artifacts and greatly destroy the uniformity of the optical system. It has been well-known for many decades of optical engineering that the easiest way to deal with this is to institute surface scattering or absorption of these stray rays. Since the flat conical bottom surface 91 C of lens 91 intercepts most of these stray Fresnel reflections, the tried-and-true traditional solution is simply to roughen the corresponding mold surface so that the Fresnel light is dissipated to become part of the above-described volume scattering. At the termination of ray 92 F 2 can be seen the scattered rays, some of which illuminate the top of substrate or printed circuit board (PCB) 99 , which of course could also be scattered by using a white diffuse white paint, say on the PCB. Another method that leads to some loss in overall optical efficiency of the system is to simply paint the bottom of the lens or the PCB with a highly absorbing black paint. This method has been found to produce excellent uniformity by these inventors for the illumination on LCD screens or for the reach-in refrigeration application, where really good uniformity on the illuminated packages has been produced.
FIG. 10 shows graph 100 with abscissa 101 denoting distance in millimeters from the center of the lens of FIG. 9 and ordinate 102 denoting illuminance relative to the pattern maximum (in order to generalize to any illumination level). Dashed curve 103 is the ideal illumination pattern desired for the configuration of FIG. 7 , given an inter-lens spacing of 125 mm and a target distance of 23 mm. These dimensions represent a backlight application, where the LEDs are arrayed within a white-painted box, and the target is a diffuser screen, with a liquid-crystal display (LCD) just above it. Increased LED luminosity mandates fewer LEDs, to save on cost, while aesthetics push for a thinner backlight. These two factors comprise a design-pressure towards very short-throw lighting.
The ‘conical pattern’ of curve 103 and its converse (not shown) from an illuminator 31 at 125 mm, will add to unity, which assures uniform illumination. Dash-dot curve 104 depicts the combined parasitic illuminance on that target plane caused by the above-discussed volume and surface scattering from a lens at x=0. This curve is basically the cosine 4 of the off-axis angle to a point on the target. Solid curve 105 is the normalized difference between the other two curves, representing the pattern that when scaled will add to curve 104 to get a total illuminance following curve 103 . In this case the scattered light of curve 104 is strong enough to deliver 100% of the required illuminance just above the lens. In such a case the central cusp 82 of FIG. 8 will ensure that the central illuminance is zero when only counting direct light that is delivered through the lens.
The illumination pattern represented by curve 105 of FIG. 10 can be used to numerically generate the inner and outer profiles of the lens 81 of FIG. 8 , utilizing rays from the right and left edges of the source. Dotted curve 106 of FIG. 10 graphs the relative size of the source image height (as shown in FIG. 6A-F ) required by the illuminance pattern of curve 105 . This height function is directly used to generate the lens profiles.
FIG. 11 shows LED 110 and illumination lens 51 , of 20 mm diameter, sending right ray 112 and left ray 113 to point 114 , which has coordinate x on planar target 115 , located 23 mm above LED 110 . Right ray 112 hits point 114 at slant angle γ, and left ray 113 at slant angle γ+Δγ. In the two-dimensional analysis of FIG. 11 , the illuminance I(x) at point x is proportional to the difference between the sines of the left and right rays' slant angles:
I ( x )α sin(γ+Δγ)−sin(γ)
This angular requirement can be met by the proper height H of the source image, namely the perpendicular spacing between right ray 112 and left ray 113 , at the lens exit of 112 . Curve 106 of FIG. 10 is a plot of this height H, relative to its maximum value. From this geometric requirement the lens profiles can be directly generated by an iterative procedure that adds new surface to the previously generated surface.
FIG. 12 shows incomplete illumination lens 51 , positioned over LED 120 . It is incomplete in that it represents a typical iteration-stage of generating the entire lens of FIG. 11 . The portion of Lens 111 of FIG. 11 that is shown as a slightly thickened curve terminates at its intersection, shown as point 124 , with right ray 122 . In FIG. 12 , a new left ray 123 is launched that is barely to the right of left ray 113 of FIG. 11 . After going through terminal point 126 and then through previously generated upper surface 121 , it will intercept the target (not shown) at a new point x+dx, just to the right of point x of FIG. 10 . This point will have an already calculated source-height requirement such as curve 105 of FIG. 19 , fulfilled by launching a new right ray 122 from x+dx. Ray 122 will intercept the lens surface at point 125 , upon new surface that has been extended from point 124 . The new surface has a slope determined by the necessity to deflect ray 122 towards point 126 on the interior surface of lens 121 . The location of this point 127 is determined by right ray 122 -S coming from the right edge of LED chip 120 C. The off-axis angle of this ray is determined by the usual requirement that the angular-cumulative intensity of right ray 122 S equal the spatially cumulative illumination at point x+dx, which is known from the desired illumination pattern, such as that shown by curve 105 of FIG. 10 . The slope of this new interior surface, from point 126 to new point 127 , is determined by the necessity of refracting ray 122 S so it joins ray 122 to produce the proper source-image height for the illumination of the target at point x+dx. In this fashion, the generation of lens 121 will be continued until all rays from chip 120 C are sent to their proper target coordinates, and its full shape is completed.
The profile-generation method just described is two-dimensional and thus does not account for skew rays (i.e., out-of-plane rays), which in the case of a relatively large source can give rise to noticeable secondary errors in the output pattern, due to lateral variations in the size of the source image. This effect necessitates a fully three-dimensional source-image analysis for generating the lens shape, as shown in FIG. 13 .
The lens-generation method of FIG. 12 traces left ray 123 through the previously generated inner and outer surfaces to a target point with lateral coordinate x+dx. The pertinent variable is the height H of the source image. In three dimensions, however, rays must be traced from the entire periphery of the LED's emission window out to the target point, where they limit the image of the source as seen through the lens from that point. An illumination lens 51 acts to alter the sources' apparent size from what it would be by itself. The size of the source image is what determines how much illumination the lens will produce at any target point.
FIG. 13A is a schematic view from above of circular illumination lens 51 , with dotted lines showing is incomplete, its design iteration having only extended so far to boundary 131 . Circular source 132 is shown at the center of lens 130 , and oval 133 represents the source image it projects to target point x+dx (not shown). This source image is established by reverse ray tracing from the target point back through the lens to the periphery of the source. The source image is the oval outline 133 on the upper surface where these rays intercept it. Thus the already completed part of the lens will partially illuminate the target point, and a small element of new surface must be synthesized for full illumination.
FIG. 13B is a close-up view showing source ellipse 133 and boundary 131 , also showing curve 134 , representing a small element of new surface that will be added in order to complete source image 133 and achieve the desired illumination level at target point x+dx. Of course, when new upper surface is added there will have to be a corresponding element of new lower surface added as well. Just as enough there must be enough new upper surface to finish the source image, so too must there be enough lower surface to provide the source image to the upper surface. Since both the extent and slope of this new lower surface must be determined as free variables, the design method must be able to calculate both unknowns, but in general the slopes of the new elements of upper and lower surface will be smooth continuations of the previous curvatures of the surfaces.
Traditionally, non-imaging optics deals only with rays from the edge of the source, but the illumination lenses 51 disclosed herein go beyond this when assessing the source image at each target point. The incomplete source image of FIG. 13B gives rise to a less-than-required illuminance at the target point of interest, at lateral coordinate x. In order to calculate this illuminance, however, rays must be reverse traced back to the entire source, not just its periphery. This is especially true when the source has variations in luminance and chrominance. Then the flux from each small elemental area dA of FIG. 13B is separately calculated and integrated over the source image as seen through already completed surface. The deficit from the required illuminance will then be made up by the new surface 134 of FIG. 13B . Its size is such that the additional source image area will just finish the deficit. When the illumination pattern only changes gradually, as with the linear ramps just discussed, the deficit is always modest because the previously generated surface has done a good job of getting close to the required illuminance. The new surface will not have to scrunch the new source image, due to a tiny deficit, nor expand it wildly for a large deficit, because the target pattern is ‘tame’ enough to prevent this.
This design method can be called ‘photometric non-imaging optics’, because of its utilization of photometric flux accounting in conjunction with reverse ray tracing to augment the edge-ray theorem of traditional non-imaging optics.
The iterative process that numerically calculates the shape of a particular illumination lens 51 can begin, alternatively, at either the center or the periphery. If the lens diameter is constrained, the initial conditions would be the positions of the outer edges of the top and bottom surfaces, which then totally determines the lens shape, in particular its central thickness. If this thickness goes below a minimum value then the initial starting points must be altered. While this is conceptually feasible, in practical terms it leaves the problem underdetermined, whereas the reverse ray tracing of FIG. 13A utilizes the previously generated surface via reverse ray tracing. Thus it is easier to begin the design iteration at the center of the lens using some minimum thickness criterion, e.g., 0.75 mm. The height of the lens center above the source would be the primary parameter in determining the overall size of the lens. The other prime factor is how the central part of the lens is configured as a negative lens, that is, whether concave-plano, concave-concave, or plano-concave. Also, a concave surface can either be smooth or have the cusp-type center as shown in FIG. 8 , in the case of strong parasitic losses.
FIG. 14 shows concave-plano lens-center 140 , to be used as a seed-nucleus for generating an entire illumination lens 51 . Its diameter is determined by the width of ray fan 141 , which propagates leftward from the target center (not shown) x=0 at a distance of 23 mm above (to the right of) LED chip 142 , the size of which has been exaggerated for clarity. Ray fan 141 has the width necessary to achieve the desired illumination level at the center of the target, and in short-throw lighting this is less than what the LED would do by itself. This means the central part of the illumination lens 51 must demagnify the source, which is why the lens-center is diverging, with negative focal length. In fact, the very function of lens-center 140 is to provide the proper size of source image (of which ray fan 141 is a cross-section) for the target center, x=0.
FIG. 14 also shows expanding ray fan 143 , originating at the left edge of chip 142 . The will mark the upper edge of a source image as seen from the x-positions at which these left rays intercept the target plane (not shown, but to the right). These rays exemplify how edge rays are sent through previously established surfaces.
FIG. 15 shows concave-concave lens-center 150 , central ray-fan 151 , chip 152 , and left-ray fan 153 . The lens surfaces have about half the curvature of the concave surface of FIG. 14 .
FIG. 16 shows plano-concave lens-center 160 , central ray-fan 161 , chip 162 , and left-ray fan 163 .
In the progression from FIGS. 14 to 16 , the lowest left ray (the one with an arrow) lies at a shrinking slant angle ψ, indicating different illumination behavior and setting a different course towards the final design. All three configurations produce the same illuminance at target x=0, that is to say the same size source image, as shown by the ray fans 141 , 151 , & 161 being of identical size as they arrive at each lens, which is equivalent to saying they produce the same target illuminance at center x=0.
FIG. 17 shows illumination lens 51 , numerically generated from a concave-plano center-lens, as in FIG. 14 . Planar source 171 is the light source from which it was designed.
FIG. 18 shows illumination lens 51 , numerically generated from a concave-concave center-lens, as in FIG. 15 . Planar source 181 is the light source from which it was designed.
FIG. 19 shows illumination lens 51 , numerically generated from a plano-concave center-lens, as in FIG. 16 . Planar source 191 is the light source from which it was designed.
These three lenses were designed utilizing rays from the periphery of the light source, in this case circular. The size of the lens is a free parameter, but etendue considerations dictate that a price be paid for a lens that is too small. In the case of a collimator, the output beam will be inescapably wider than the goal if the lens is too small. In the case of the short-throw illumination lenses 51 disclosed herein, the result will be an inability to maintain an output illumination pattern that is the ideal linear ramp of curve 103 of FIG. 10 , because it requires the source image of curve 106 . If the lens is smaller than the required source image size, then it cannot supply the required illumination. Thus the lens size will be a parameter fixed by the goal of a linear ramp. Lenses that are too small will have some rays trapped by total internal reflection instead of going to the edge of the pattern. If this is encountered in the design process then the iteration will have to re-start with a greater height of the lens-center above the LED.
In conclusion, the preferred embodiments disclosed herein fulfill a most challenging illumination task, the uniform illumination of close planar targets 115 by widely spaced lenses. Deviations from this lens shape that are not visible to casual inspection may nevertheless suffice to produce detractive visual artifacts in the output pattern. Experienced molders know that sometimes it is necessary to measure the shape of the lenses to a nearly microscopic degree, so as to adjust the mold-parameters until the proper shape is achieved. Experienced manufacturers also know that LED placement is critical to illumination success, with small tolerance for positional error. Thus a complete specification of a lens shape necessarily requires a high-resolution numerical listing of points mathematically generated by a fully disclosed algorithm. Qualitative shape descriptors mean nothing to computer-machined injection molds, nor to the light passing through the lens. Unlike the era of manual grinding of lenses, the exactitude of LED illumination lens 51 slope errors, means that without an iterative numerical method of producing these lens-profile coordinates, there can be no successful lenses produced.
The preceding description of the presently contemplated preferred embodiments is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The full scope of the invention should be determined with reference to the Claims. | A circular LED illumination lens for short throw lighting, for example, as part of a set of such devices installed on mullions in reach-in refrigerator cabinets, to uniformly light access across the rectangular door and shelves. The lens has an upper surface with a cavity for the LED, an upper surface the shape of a toroid, generated by an elliptical arc, that serves to magnify the light rays from the LED in an outboard direction, and the minor axis tilted about 17 degrees relatives the center axis of the LED which serves to direct the rays at the center of the shelves. The upper surface also preferably includes a spherical dimple to direct light away from the center axis. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application having Ser. No. 60/957,113, filed on Aug. 21, 2007, which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention generally relate to systems and methods for oil field cutting bioremediation. More particularly, embodiments of the present invention relate to systems and methods for bioremediation of hydrocarbon contaminated drill cuttings from oil and gas wellbores.
[0004] 2. Description of the Related Art
[0005] The drilling of wells in the recovery of oil and gas typically comprises a rig drilling the well with a hollow drill string. As the well is being drilled, drilling fluids are pumped down the bore of the string. The drilling fluid passes through openings in the drill bit and returns to the surface through the annulus surrounding the string, carrying the cuttings produced by the drill bit. The drilling fluid is then recycled to remove the cuttings so that it may be used again.
[0006] Traditional methods of recycling drilling fluid include using a centrifuge to separate the liquid from the cuttings. In large drilling operations, to keep up with the volume of drilling fluid used, it is necessary to use either a very large centrifuge or to use a plurality of centrifuges. In either case, the cost of operating such a drilling fluid recycling system is substantial.
[0007] Fluid recycling system using setting tanks and centrifuges have been used. The settling tank is used as a preliminary step to settle the cuttings from the fluid. The drill cuttings often remain in suspension in the fluid and are often referred to as “solids.” Flocculating agents may be introduced into the tank to assist in the settling of the solids. The drilling fluids are pumped into the receiving end of the tank. The tank has a plurality of transverse walls or baffles that form a plurality of compartments within the tank. Each wall has an opening to permit the flow of fluid from an upstream compartment to a downstream compartment. The openings are positioned on the walls in such a manner that the fluid follows a sinuous path as it flows from the receiving end to the collecting end of the tank. As fluid flows from compartment to compartment, solids in the fluid settle to the bottom of the tank.
[0008] Once fluid reaches the collecting end of the tank, it is withdrawn from the tank to be re-used in the drilling operation. The settled or separated solids are conveyed towards the receiving end of the tank using an auger. A slurry of settled solids and fluid are withdrawn from the tank and pumped through a centrifuge. Fluid recovered from the centrifuge is re-introduced into the tank at the receiving end.
[0009] While using the combination of settling tank and centrifuge is an improvement in comparison to using a centrifuge by itself, in practice, this circuit is often unable to keep up with the throughput of drilling fluid required in drilling a well. It is often necessary to temporarily stop drilling until the settling tank and centrifuge can catch up and recover enough drilling fluid for the drilling operation.
[0010] Therefore, there is a need for a new system and method for recovering and recycling drilling fluid in sufficient quantity for typical drilling operations.
SUMMARY OF THE INVENTION
[0011] Apparatus and methods for bioremediating hydrocarbon contaminated solids. In at least one specific embodiment, the method can include introducing a slurry comprising one or more drilling fluids and one or more hydrocarbon contaminated solids to a settling system. The settling system can include one or more housings having a receiving compartment at a first end thereof and a collecting compartment at a second end thereof. A barrier can be disposed in the receiving compartment, and at least one wall can be transversely disposed in the housing between the receiving and collecting compartments. The wall can have at least one aperture formed therethrough and at least one flow-restricting baffle disposed thereon, wherein the one or more baffles can extend perpendicularly from the wall. The slurry can flow across the barrier, and the hydrocarbon contaminated solids in the slurry can be separated from the drilling fluid by causing the slurry to reverse direction and flow around the barrier. The separated hydrocarbon contaminated solids can be contacted with one or more microorganism populations disposed between the receiving compartment and the collecting department.
[0012] In at least one specific embodiment, the apparatus can include a housing having a receiving compartment at a first end thereof and a collecting compartment at a second end thereof. A substantially vertical flow-reversing barrier can be disposed in the receiving compartment. The barrier can be adapted to receive a slurry containing drilling fluid and one or more hydrocarbon contaminated solids, the barrier can be capable of causing the slurry to reverse direction and flow around the barrier and can cause at least some of the solids in the slurry to separate from the drilling fluid. At least one wall can be transversely disposed in the housing between the receiving and collecting compartments. The wall can have at least one aperture formed therethrough and at least one flow-restricting baffle disposed thereon, wherein the one or more baffles can extend perpendicularly from the wall. One or more microorganism populations can be present to selectively remove the hydrocarbons from the separated solids. A conveyor can be used for moving the separated solids from the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] 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.
[0014] FIG. 1A depicts a perspective view of a system for bioremediation of hydrocarbon contaminated solids from oil and gas wellbores, according to one or more embodiments.
[0015] FIG. 1B depicts a plan view of an illustrative settling system for separating solids from a used drilling fluid, according to one or more embodiments.
[0016] FIG. 2 depicts a partial cross section view of the settling system depicted in FIG. 1B .
[0017] FIG. 3 depicts a cross-sectional end view of the settling system along lines III-III shown in FIG. 2 .
[0018] FIG. 4 depicts a perspective view of the flow-reversing barrier of the settling system depicted in FIG. 1B , according to one or more embodiments.
[0019] FIG. 5 depicts a front elevation view of the flow-reversing barrier of the settling system depicted in FIG. 1B , according to one or more embodiments.
[0020] FIG. 6 depicts a top plan view of the flow-reversing barrier of the settling system depicted in FIG. 1B , according to one or more embodiments.
[0021] FIG. 7 depicts a side elevation view of the flow-restricting baffle of the settling system depicted in FIG. 1B , according to one or more embodiments.
[0022] FIG. 8 depicts a perspective view of the flow-restricting baffle of the settling system depicted in FIG. 1B , according to one or more embodiments.
[0023] FIG. 9 depicts a front elevation view of the flow-restricting baffle of the settling system depicted in FIG. 1B , according to one or more embodiments.
[0024] FIG. 10 depicts a top plan view of the flow-restricting baffle of the settling system depicted in FIG. 1B , according to one or more embodiments.
[0025] FIG. 11 depicts a side elevation view of the flow-restricting baffle of the settling system depicted in FIG. 1B , according to one or more embodiments.
DETAILED DESCRIPTION
[0026] A detailed description will now be provided. Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the “invention” may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the “invention” will refer to subject matter recited in one or more, but not necessarily all, of the claims. Each of the inventions will now be described in greater detail below, including specific embodiments, versions and examples, but the inventions are not limited to these embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the inventions, when the information in this patent is combined with available information and technology.
[0027] FIG. 1A depicts a plan view of an illustrative system 100 for bioremediation of hydrocarbon contaminated solids from oil and gas wellbores, according to one or more embodiments. In one or more embodiments, the system 100 can include one or more wellbores 110 , drilling fluid pumps 115 , mud tanks 120 , mixing tanks 130 , shakers 140 , centrifuges 150 , disposal bins 160 , and settling system 10 . Drilling fluid from the mud tanks 120 can be conveyed to the one or more wellbores 110 via the pump 115 . Used drilling fluids and solids, such as drill cuttings, sand, gravel, and other particulates, from the wellbore 110 can be sent to and collected in the shaker 140 via line 112 .
[0028] The shakers 140 can be any device or mechanism capable of separating liquids from solids. In one or more embodiments, the shaker 140 can have a wire cloth screen that vibrates as the drilling fluid and solids flow on top of the screen. The liquid and solids having a particle size less than the mesh openings can pass through the screen, while larger solids are retained on the screen. Those larger solids that are not allowed to pass through the mesh can eventually fall off the back of the shaker 140 into the disposal bins 160 via line 142 or simply allowed to pile behind the shaker 140 . Such disposal pile can be removed for treatment and/or disposal.
[0029] From the shakers 140 , the used drilling fluid having smaller solids contained therein is sent to the settling system 10 via line 145 . The settling system 10 can include two or more zones or compartments 11 to separate the solids from the liquids. The settling system 10 is explained in more detail below. In operation, each zone 11 provides a torturous path and pressure drop for the drilling fluid having the solids dispersed therein, allowing the solids to drop while passing along the liquid phase. The liquid phase can flow through the settling system 10 to the one or more centrifuges 150 , which can separate any fines or smaller particles that remain entrained in the drilling fluid. The drilling fluid that is free or essentially free of any solids can be returned to the mud tanks 120 via line 155 for subsequent drilling operations. The separated solids or fines from the centrifuges 150 can be directed to the one or more disposal bins 160 via line 165 , where the contents therein can be removed for treatment and/or disposal.
[0030] In one or more embodiments, any one of the one or more zones 11 can include one or more microorganism populations to selectively remove any hydrocarbons from the separated solids that collect at the bottom thereof. As mentioned above, the hydrocarbon-containing solids or hydrocarbon contaminated solids in the used drilling fluids separate and settle at the bottom of the settling system 10 while the liquid phase passes over a top portion thereof. A hydrocarbon-containing solid or hydrocarbon contaminated solid can contain as much as 99 wt % hydrocarbon. Such solids can contain of from 1 wt % to 99 wt %; or 5 wt % to 95 wt %; or 10 wt % to 90 wt %; or 15 wt % to 85 wt %; or 20 wt % to 80 wt %; or 30 wt % to 70 wt %; or 40 wt % to 60 wt %; or about 50 wt % hydrocarbon. Such solids can have a mesh size of 200 or less, such as 190 or less, 180 or less, 170 or less, 160 or less, 150 or less, 140 or less, 130 or less, 120 or less, 110 or less, 100 or less, or 50 or less.
[0031] The solids are typically slurried in the bottom of the settling system 10 with some of the drilling fluid that remains in the bottom. The microorganisms can convert the hydrocarbons on or entrained in the solids into carbon dioxide, water, and/or biomass. The resulting biomass can be disposed or further converted to useful energy. For example, the biomass can be used in conjunction with a gasification system to produce a syngas.
[0032] Suitable microorganisms have a particular appetite for hydrocarbons. As such, the microorganisms are selective toward hydrocarbons and not drilling fluids. Illustrative microorganisms include but are not limited to bacteria and fungi. Preferred microorganisms are commercially available from Rapid Energy Services.
[0033] As used herein, the term “drilling fluid” refers to any fluid that is not a hydrocarbon that is used in hydrocarbon drilling operations, including muds and other fluids that contain suspended solids, emulsified water or oil. The term “mud” as used herein refers to all types of water-base, oil-base and synthetic-base drilling fluids, including all drill-in, completion and work over fluids.
[0034] FIG. 1B depicts a plan view of an illustrative settling system 10 for separating solids from a drilling fluid, and FIG. 2 depicts a partial cross section view of the settling system 10 , according to one or more embodiments. The settling system 10 can include one or more settling tanks or housings 12 arranged in parallel or series. Each settling tank 12 can include a first end wall 8 , a second end wall 9 , side walls 13 , and a bottom 19 . The settling tank 12 can have a shape that is rectangular, square, spherical, or the like. In one or more embodiments, the settling tank 12 is rectangular having a length to width ratio of at least 5:1 (5 to 1), such as 6:1; 7:1; 8:1; 9:1; or 10:1. The height of the settling tank 12 can vary depending on the volume of drilling fluid to be processed. In one or more embodiments, the settling tank 12 has a height of about 1 foot or more, such as 3 ft, 5 ft, or 10 ft or more. In one or more embodiments, the settling tank 12 has the capacity to handle at least 10,000 gallons of fluid, such as 12,000 gallons or more, 15,000 gallons or more, or 20,000 gallons of more.
[0035] In one or more embodiments, the settling tank 12 can include two or more dividing or transverse walls 15 (three are shown) defining two or more zones therebetween. In one or more embodiments, a first transverse wall 15 can define the receiving zone 14 adjacent to the first end wall 8 ; a second transverse wall 15 can define the collecting zone 16 adjacent the second end wall 9 ; and a third transverse wall 15 can define the two intermediate zones 18 between the receiving zone 14 and the collecting zone 16 . The transverse walls 15 can define and separate the receiving zone 14 , intermediate zones 18 , and collecting zone 16 , which are within the tank 12 . Each transverse wall 15 can have an aperture or opening 23 located near or at the top thereof. In one or more embodiments, each opening 23 can be approximately 12 inches high by 18 inches wide. A flow-restricting baffle 22 can be mounted on the downstream side of each transverse wall 15 and can be aligned with the opening 23 .
[0036] In one or more embodiments, the settling system 10 can include one or more mixing zones 36 disposed or otherwise attached to the tank 12 at an end opposite the receiving zone 14 . The mixing zone 36 can contain one or more mixers 37 , as best depicted in FIG. 2 . As discussed in more detail below, the used drilling fluid having solids disposed therein can be mixed with one or more additives or agents in the mixing zone 36 to facilitate separation of the solids from the liquids. For example, the mixer 37 can be used to prepare a flocculating chemical agent that assists in settling solids from the drilling fluid. In one or more embodiments, the microorganisms can be added to the drilling fluid within the mixing zone 36 .
[0037] The used drilling fluid containing one or more solids can be collected in the holding tank 24 . The drilling fluid can be pumped or allowed to gravity flow from the holding tank 24 into the receiving zone 14 and can be directed towards the flow-reversing barrier 20 via the inlet 26 . In one or more embodiments, the used drilling fluid can be sent directly to the receiving zone 14 . Within the receiving zone 14 , the fluid flow is impeded or stopped by the flow-reversing barrier 20 and reversed around the side panels. The flow-reversing barrier 20 can be supported by a bar 40 that can run transverse across the top of the settling tank 12 . The flow-reversing panel 20 can be best understood with reference to FIGS. 4-7 . The reversal of fluid flow causes heavier solids to settle to the bottom 19 of the settling tank 12 , within the troughs 38 and 60 . As the fluid level rises in the receiving zone 14 , the fluid can overflow into the adjacent downstream intermediate zones 18 through the openings 23 in the transverse walls 15 . The fluid that flows through the openings 23 encounters the flow-restricting baffles 22 and deflects downwards to the bottom 19 of the tank 12 . The flow of the fluid through the baffle 22 causes solids in the fluid to settle to the bottom of settling tank 12 . Fluid can flow from zone to zone, by passing through successive baffles 22 in each transverse wall 15 , until the fluid reaches the collecting zone 16 . Fluid can be withdrawn from the collecting zone 16 , by the pump 34 , to be used again in the drilling operations, recycled to the holding tank 24 , and/or the receiving zone 14 .
[0038] The solids that have settled to the bottom 19 of settling tank 12 can be conveyed by the augers 30 and 31 through the troughs 38 and 60 towards the collecting zone 16 . The augers 30 and 31 can expel a slurry of solids and fluid through the outlets 32 on the end wall 9 . The augers 30 and 31 can be rotated by drive mechanism 28 . The interaction between augers 30 and 31 and the drive mechanism 28 can be best understood with reference to FIG. 3 . In one or more embodiments, the outlets 32 can be coupled to one or more pipes 33 . Each pipe 33 can be about 10 inches in diameter. The pipes 33 can extend to intersect with the plenum 56 . The plenum 56 can be made of 10 inch diameter pipe. The plenum 56 can have one or more end covers 57 . The end covers 57 can be removable to allow for cleaning-out of the plenum 56 . The plenum 56 can receive the slurry discharged from the outlets 32 and direct the slurry to the centrifuge 150 via the discharge ports 58 . The ports 58 can be about 4 inches in diameter and can be connected via tubes, pipes or hoses (not shown) to a pump (not shown) to transfer the slurry to the centrifuge 150 .
[0039] In one or more embodiments, drilling fluid can be skimmed from the collecting zone 16 and mixed with one or more chemicals, agents, and/or microorganisms in the mixer 37 . The resulting mixture can be pumped via pump 34 to the receiving zone 14 , i.e. recycled, to mix with the received drilling fluid and assist in the settling of solids contained therein. In one or more embodiments, the settling system 10 can include a walkway or grating 64 . The walkway or grating 64 can be mounted on a sidewall 13 to permit an operator to inspect the fluid as it passes through settling tank 12 . One or more sampling stations for collecting and measuring the hydrocarbon content of the slurry can be located along the sidewall 13 .
[0040] Referring to FIG. 3 , the bottom wall 19 of the settling tank 12 in combination with one or more inverted V-shaped ribs 62 can form one or more troughs (two are shown 38 , 60 ) that run lengthwise along the tank 12 from the first end wall 8 to the second end wall 9 . In troughs 38 and 60 , respectively, one or more augers (two are shown 30 , 31 ) can be used to move settled solids towards the outlets 32 located on the second end wall 9 . In at least one specific embodiment, each auger 30 and 31 can be 10 inches in diameter and have a pitch of 10 inches. The augers 30 and 31 can be operated at any speed depending on the requirements of the drilling operation. For example, the augers 30 and 31 can be designed to turn at approximately 9 revolutions per minute or more.
[0041] Each drive mechanism 28 can include an electric motor in the 2 to 3 horsepower range coupled to a gearbox (not shown). The output of the gearbox can be coupled to each auger via a belt and pulley system (not shown). To synchronize the augers 30 and 31 to turn at the same rate, each auger 30 and 31 can have a chain sprocket and can be coupled to one another via a drive chain (not shown). It should be obvious to one skilled in the art that drive mechanism 28 can also use an internal combustion engine or a hydraulic drive system as the motive power to turn the augers. It should also be obvious that the gear ratio of the gearbox and the pulley sizes are dependent on the type of motive power used in order to obtain the desired turning rate of the augers 30 and 31 .
[0042] Referring to FIGS. 4 , 5 , 6 and 7 , the flow-reversing barrier 20 can have a vertical main back panel 46 and two vertical side panels 42 perpendicular to the back panel 46 . The barrier vertical main back panel 46 and the two vertical side panels 42 can form a U-shaped structure. The flow-reversing barrier 20 can also have a bottom plate 44 disposed between the vertical side panels 42 . The bottom plate can extend from the back panel 46 and along the bottom edge of the vertical side panels 42 . The top of the flow-reversing barrier 20 can be supported by the support bar 40 . The bottom plate 44 can rest on top of the v-shaped rib 62 . One or more struts 41 can further support the flow-reversing barrier 20 . The struts 41 can extend diagonally upward from the rib 62 to the bottom edge of the back panel 46 . The top of the flow-reversing barrier 20 can be substantially flush with the top of the tank 12 .
[0043] Referring to FIGS. 8-11 , each flow-restricting baffle 22 can include a vertical back plate 52 and two vertical side walls 50 perpendicular to the vertical back plate 52 . The vertical side walls 50 are preferably arranged in a U-shape. In one or more embodiments, each vertical side wall 50 can be approximately 24 inches high by 8 inches wide. Each vertical side wall 50 of the flow-restricting baffle 22 can have two or more horizontal openings (five are shown) 54 stacked vertically on side wall 50 . In one or more embodiments, each horizontal opening can be approximately 6 inches wide by 2 inches high. When the fluid encounters the flow-restricting baffles 22 , as described above, the fluid will strike the vertical back plate 52 . Fluid can also pass through the slots 54 in the side walls 50 of the flow-restricting baffle 22 . The interaction between the fluid and vertical back plate 53 and slots 54 can increase the rate at which solids are removed from the fluid.
[0044] The settling system 10 can incorporate the use of microorganisms to help to remove hydrocarbons from the solids deposited on the bottom 19 of settling tank 12 . The microorganisms can be located within the troughs 38 and 60 at the bottom of the settling tank 12 . After a given period of time, i.e. a sufficient time for the microorganisms to convert the hydrocarbons therein to water and carbon dioxide, the augers 30 and 31 can be used to empty the tank 12 . A water flush can also be used. Afterwards, the tank 12 can be re-loaded with a fresh microorganism population and ready to process another batch of used drilling mud with cuttings.
[0045] The bioremediation of the solids in the settling tank 12 can also be continuous by employing two trains of settling tanks 10 working in parallel. One tank 12 can be off-line in clean-out mode while the other tank 12 can be in operation. This allows one tank 12 to operate at all times while the other is being flushed and/or re-loaded with the bioremediation material.
[0046] The bioremediation process can be controlled by controlling the temperature, pH, and moisture levels within settling tank 12 . In addition, the augers 30 and 31 can be useful in the bioremediation process by providing mechanical agitation to stimulate the microorganism population. The augers 30 and 31 can be co-rotating or counter-rotating depending on the amount and/or degree of agitation desired within the settling tank 12 . The moisture level can be controlled by adding or removing water to the various zones of the settling tank 12 . Other nutrients can also be added to the settling tank 12 , if needed, to accelerate or enhance the remediation process and/or to control the pH of the hydrocarbon contaminated drill cuttings.
[0047] In one or more embodiments, the microorganism population can be located in the collecting zone 16 . After the solids have had sufficient time to settle toward the bottom 19 of the tank 12 , the augers 30 and 31 can be activated to push the settled slurry to the collecting zone 16 , as described above. In the collecting zone 16 , the microorganisms can contact the solids slurry and degrade the hydrocarbon contaminated solids. In this configuration, the settling system 10 can be operated continuously with only a single tank 12 . For example, the single settling tank 12 can have zones 14 and 18 with enough capacity to handle a rate of used drilling fluid that is commensurate with the rate of remediation in the collecting zone 16 .
[0048] In one or more embodiments, the system 10 can accommodate a flow rate of drilling fluid in the range of 1 to 500 gallons per minute. It should be obvious to those skilled in the art that the size of the settling tank 12 and the volume of each zone is a function of the volume of drilling fluid to be recycled and the amount of solids that need to be removed from the drilling fluids to facilitate their reuse. The size and dimensions of the settling tank 12 can be scaled larger or smaller, accordingly, to suit the associated drilling operation. The number of transverse walls within the settling tank 12 can be varied, as necessary, to accommodate the volume of drilling fluid required for the drilling operations.
[0049] Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges from any lower limit to any upper limit are contemplated unless otherwise indicated. Certain lower limits, upper limits and ranges appear in one or more claims below. All numerical values are “about” or “approximately” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.
[0050] Various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted.
[0051] 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. | Apparatus and methods for bioremediating hydrocarbon contaminated solids. The method can include introducing a slurry comprising one or more drilling fluids and one or more hydrocarbon contaminated solids to a settling system. The settling system can include one or more housings having a receiving compartment at a first end thereof and a collecting compartment at a second end thereof. A barrier can be disposed in the receiving compartment, and at least one wall can be disposed transversely in the housing between the receiving and collecting compartments. The wall can have at least one aperture formed therethrough and at least one flow-restricting baffle disposed thereon, wherein the one or more baffles extend perpendicularly from the wall. The separated hydrocarbon contaminated solids can be contacted with one or more microorganism populations disposed between the receiving compartment and the collecting department. | 4 |
This application is a continuation-in-part of copending application Ser. No. 07/646,949 filed Jan. 30, 1991, now U.S. Pat. No. 5,240,454.
BACKGROUND OF THE INVENTION
This invention relates to the art of butchering, and more particularly to a method and apparatus for processing the legs of chickens and other poultry.
There is interest in automating various aspects of poultry processing that were previously done by hand, and in improving existing equipment, both in terms of product quality and processing speed.
In the field of poultry processing, severing legs from the body of the bird and removing the drumstick from the thigh are two chores that have been difficult to do well automatically, owing to difficult and varying geometry of these portions. Copending prior application Ser. No. 07/649,949 describes an apparatus which was particularly suited to cutting up the lower half of a chicken carcass.
This application describes a modified form of the apparatus; the modifications are at the upstream end of the apparatus (as shown in FIGS. 2-4 of the parent application), where carcasses are automatically transferred from a shackle conveyor to chain conveyors which subsequently move the product through a series of cutting stations.
SUMMARY OF THE INVENTION
Two objects of the invention are to automate the processing of chicken legs, and to reduce the frequency of misfeeds at the upstream end of a leg processing apparatus.
These and other objects of the invention are met by an automatic saddle loader for transferring poultry hocks from a first, linear shackle conveyor, supporting the hocks in a vertical plane, to a gathering wheel having a series of slots in its periphery for receiving the hocks from the shackle conveyor. The device includes a rotatable transfer disc supported on an axis oblique to the direction of movement of the shackle conveyor and intersecting its plane below the level of the hocks. This disc is situated so that its uppermost peripheral portion crosses the path of the hocks and lifts them from the shackles as it pushes them laterally away from the shackle. The disc has a circumferentially spaced array of indentations around its periphery, corresponding to the spacing of the hocks in the shackle conveyor, and a flexible bar passes substantially tangent to both the transfer disc and the gathering wheel, for holding the hocks firmly in their respective indentations until they are seated in the slots of the gathering wheel.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings,
FIG. 1 is a top plan view of an apparatus embodying the invention,
FIG. 2 is a side elevation of a transfer disc shown in FIG. 1,
FIG. 3 is an oblique view of the transfer disc of FIG. 2, taken along its axis of rotation,
FIG. 4 is a side elevation of a transfer paddle appearing in FIG. 1,
FIG. 5 is an end view thereof,
FIG. 6 is a side elevation of a saddle inverter disposed just downstream of the transfer paddle, and
FIG. 7 is a top plan view thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 provides an overall plan view of an apparatus embodying the invention. The apparatus is complex, so in this view, and throughout the drawings, detail not important to an understanding of the invention has been omitted so that the invention can be clearly explained.
The apparatus comprises a frame 10, shown diagrammatically in FIG. 1, which supports the subassemblies of the invention. Breaking the invention down to functional components, there are, in sequence, a transfer unit 12, a nicking unit 14, an inverting unit 16, a tearing unit 17, and a splitting unit 18. The location of each unit is indicated generally in FIG. 1. Arrows denote the direction of product flow through the apparatus. Only the transfer unit is described in detail below.
The transfer unit comprises a conventional shackle conveyor 20 running along a predetermined horizontal path from a location at which birds have been slaughtered, plucked, gutted, and divided into halves. The upper half of each bird (breasts, wings, upper portion of back) has been directed elsewhere, leaving the whole legs interconnected by lower portion of back (together referred to hereafter by the accepted term "saddle") suspended from the shackles by its hocks (the enlarged lower portions corresponding to the human ankle). The apparatus then separates the legs from the back, and finally severs the drumsticks from the thighs. (The severing portion of the apparatus is not new, having been previously patented by the present applicant; nevertheless, it is described herein to give a whole picture of the apparatus.)
When it reaches the present apparatus, the shackle conveyor path passes around a portion (e.g., 90°) of the periphery of a large sprocket 22, which is formed from a horizontal disc of polymeric material such as ultra-high molecular weight polyethylene, mounted on a vertical main axle 24 supported at either end by bearings (not shown) connected to the frame. The disc has studs 26 protruding from its periphery at intervals corresponding to the pitch of the conveyor, the studs being designed to penetrate openings existing in the shackle conveyor, to interconnect the apparatus and the shackle line. The apparatus could derive its power from the shackle line in this way, but we prefer to provide the apparatus with its own motor 28, so that the conveyor line is not greatly loaded when the apparatus is inserted into it. When the apparatus is self-powered, the studs serve primarily to maintain proper registration between the shackle conveyor and the disc. The motor 28 is a standard hydraulically-driven unit mounted atop the frame on an axis parallel to the main axle, and drives a large polymeric gear 30 atop the disc through a reduction gearset (not shown). Bearings and other details of these components have been omitted from the drawings, for clarity.
Below the sprocket 22, at the level of the hocks in the shackles, there is a peripherally slotted gathering wheel 34 whose lower peripheral edge 36 is undercut at 38 for a purpose described below. The gathering wheel, around its periphery, has a series of pairs of slots whose spacing corresponds to that of the shackles, and whose width (about 5/8 inch) is greater than the leg bones, but narrower than the hocks, so that once the legs are transferred into the slots, the saddles remain supported by the hocks.
The undercut 38 (see FIG. 2) accommodates an arcuate guide bar 41 whose function is to keep the hocks in the slots of the wheel after they have been transferred. The guide bar starts outside the outer diameter of the slotted disc just upstream of the point of tangency between the shackle conveyor and the disc, but otherwise generally lies within the undercut.
The shackles are designed, of course, to hold the hocks securely, and prevent strictly lateral withdrawal. The hocks cannot be simply pushed laterally out of the shackles; rather, it is necessary to lift them somewhat first. To do this, the apparatus includes a segmented transfer wheel 42, illustrated in FIGS. 2 and 3. FIG. 2 is a view perpendicular to a plane containing both axes, looking in the upstream direction. Only the edge of the transfer disc is seen in this view, since the shaft 44 which supports the disc lies in a radial plane of the axle, and therefore within the plane of the drawing. The shaft 44 is inclined outwardly with respect to the axle about 40°, to provide both lifting and lateral motion, and intersects the vertical plane of the shackle conveyor below the level of the hocks. The lower surface of the transfer disc just clears the upper edge of the slotted disc, which it overlaps by about an inch.
FIG. 3 shows the configuration of the transfer disc, which includes a plurality of like sectors 45, each having indentations 46, each the shape of a 60° "V", with generous radiuses and fillets. The spacing of the indentations equals that of the slots, and the disc shaft is driven at a speed sufficient to make the peripheral speeds of the slotted disc and the transfer disc approximately equal. Power is derived from a power take-off 48, represented diagrammatically by broken lines, which mechanically interconnects the two discs.
The reason for segmenting the transfer wheel is so that only every other saddle is removed from the shackle conveyor. Input can thus be continuously divided between two like processing machines. Alternatively, by changing the segmentation scheme, every third saddle could be removed at a particular processing machine.
For this apparatus, the saddles must be loaded into the shackles so that as they approach the gathering wheel, their tails are uniformly pointed toward the center of the gathering wheel, rather than away from it. The reason for this requirement will become apparent.
An important feature of the invention is the flexible "clicker" bar 49 (FIG. 7), disposed at the periphery of and just above the transfer disc. This bar secures the hocks in the indentations 46 from the time they are first engaged by the transfer disc, until they are safely retained in the pockets of the gathering wheel by element 34. Use of the clicker bar has reduced the frequency of improper transfer by two orders of magnitude.
Saddles which have thus been loaded, and transferred into the gathering wheel, are carried by it to an offloading point 50 shown in FIG. 1. The guide rod terminates just upstream of this point, so that the hocks can be removed from the slots. Directly below the offloading point, there is a paddle device 52 which kicks each saddle laterally outward, by striking the thighs. The paddle device is mounted on a shaft 54 extending laterally of the machine (i.e., horizontally, and perpendicular to the direction of subsequent product flow), the shaft being driven from the main motor by a second mechanical power take-off, again shown diagrammatically. A disc 56 is attached to the inboard end of the shaft, and a pair of L-shaped arms 58, each comprising a slotted bar with a cylindrical rod 60 welded thereto, are bolted to the disc. The slots 62 permit adjustment of the diameter of the paddle path, for different situations. The paddle, like all other moving parts of this invention, is driven continuously in synchronization with the other parts through a power take-off. Motion of the paddle is synchronized with respect to the slotted disc so that it strikes the legs just as the hocks come into registration with respective spaces formed between two pairs of identical, horizontal guide rods 64 that extend away from the slotted disc on either side of a vertical center plane "P" containing the main axle axis. The apparatus is substantially symmetrical on either side of the center plane, except as previously noted.
Within each pair of guide rods, the spacing between rods is sufficient to pass the leg bone, but not the hock; thus, these rods support the hocks during subsequent processing steps.
Since the saddles were originally loaded into the shackles so that their tails would point toward the center of the gathering wheel once they were transferred, the tails face upstream, and the backs down, as the saddles enter the guide rods. They must be reoriented so that the backs are up, and the tails downstream, to be in proper position for cutting. This reorientation is accomplished, without releasing the hocks, by an inverter 70 illustrated in FIGS. 6 and 7.
The inverter includes, in combination, an arcuate horn 72 well below the hock level; the tip of the horn is directed downstream, and is approximately even with the level of the chain conveyor which carries the saddle through the subsequent cutting stations. The upper surface of the horn comprises two wings having a dihedral angle of about 75°, whose purpose is to center the saddle, laterally. Proper lateral registration is essential to optimizing product quality.
Just above and astride the tip of the horn is a hold down guide 74, comprising a pair of spaced metal rods having a divergent-convergent configuration, as seen in FIG. 7. The hold down guide is pivotally supported at its upper end 76, and is biased downward by a spring (not shown) which allows the saddle to pass underneath.
The guide rods diverge in the downstream direction, in order to spread the legs as the back is inverted. Their downstream ends bend downward at 78 as they pass over the hold down guide, and terminate above the upstream sprocket 80 of the conveyor 82. The J-shaped loop shown in FIG. 6 represents the paths of two endless inverter chains 84, which diverge as shown in FIG. 7. The chains are driven by a motor or power take-off 85, and having flights which engage the hocks and pull them through the inverter, causing the back to roll forward 180° as it passes between the horn and the hold down guide. The rolling is assisted by the downwardly curved path of the inverter chains. The spacing between the hold down rods, where they diverge, allows the bird's tail to flip forward between them, without being bent back. The subsequent convergence keep the saddle centered by maintaining pressure on the back.
Once the saddle is inverted, the inverter chain directs it onto the surface of the conveyor chain 82, which carries it through the cutting stations.
Inasmuch as the invention is subject to this and other modifications and variations, it is intended that the foregoing description and the accompanying drawings shall be interpreted as illustrative of only one form of the invention, whose scope is to be measured by the following claims. | A chicken leg processor includes a transfer device for removing the lower portion of halved birds from a shackle conveyor, and delivering them to the conveyor chain of a cutting apparatus. The transfer device includes a segmented transfer disc which lifts the hocks from the shackles and deposits them in pockets on a horizontal gathering wheel. Subsequently, the hocks are driven out of the pockets by a paddle, and are captured between respective pairs of guide rails entering the cutting apparatus. At this point, the saddles are inverted by an overhead chain which rolls them forward into proper orientation for the cutting devices. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The invention relates to an apparatus for cutting tubes, particularly cardboard tubes.
TECHNICAL FIELD
Cardboard tube cutting machines are already known in which a cutting tool is provided which is stationary relative to the counter-holder. The cardboard tube, which is mounted on a counter-holder, is moved relative to the cutting tool by means of an ejector, the advance path relative to the cutting tool determining the tube length of a cut-off sleeve. These machines require a considerable constructional space, since their length requires at least twice the tube length of the cardboard tube to be processed.
Furthermore, an apparatus is known which has a counter-holder to receive a tube, the tube being supported freely on the counter-holder. The tube is held during a cutting process, rotating in a defined position, by means of two manually adjustable guide rollers. A horizontal holding arrangement, on which one or more cutting tools are provided, is provided above the counter-holder. These cutting tools can be actuated individually or simultaneously, so that several sleeves of the same length can be cut at fixed and uniform spacings. A separately driven stripper runs along the counter-holder to eject the sleeves. This apparatus makes it possible for several sleeves to be cut simultaneously in one cutting process, because of the multiplicity of the arranged cutting tools. However, this machine requires a time-consuming setting of the cutting tools and increased change-around times if a cut-off length of sleeves is to be produced, different from that which is set. Moreover, the minimum cut-off length is restricted by the width of the individual cutting tools. In addition, the cut-off length cannot be changed for individual sleeves during the process of cutting one cardboard tube.
SUMMARY OF THE INVENTION
The invention therefore has as its object to provide an apparatus which is of simple design, which can be selectively set to different cut-off lengths, and which makes possible a quick ejection of the cut tube sleeves after the cutting of the sleeves.
This object is attained according to the invention having a counter holder arranged to receive a tube, at least one cutting tool that is movable to a cutting position on the counter holder during a cutting process, an ejector that ejects cut-off portions of the tube, the ejector being movable relative to the counter-holder, a slide that is movable along the counter-holder, on which the at least one cutting tool and the ejector are provided, and a programmable control for freely setting cut-off lengths of tubular sleeves by moving the cutting tool on the slide.
A rational processing of a tube for the production of sleeves of different lengths is made possible by the arrangement and constitution, according to the invention, of a slide which is movable relative to the counter-holder and on which both a cutting tool and an ejector are provided. After the same or different cut-off lengths of the sleeves have been cut by means of the cutting tool, the slide is located at an end position of the tube. The ejector can now be simultaneously actuated, so that a simultaneous ejection of the sleeves from the counter-holder takes place during a return travel of the slide into its initial position for a subsequent work cycle. A displaceable element engaged by the ejector when the sleeve or sleeves is/are stripped off can be automatically guided over into an initial position of the ejector by the following introduction or pushing-on of the tube onto the counter-holder. The movement of the slide between the individual cutting processes, and also the resetting into the initial position, can be controlled by the integrated data processing equipment and controller, so that both equal and also different cut-off lengths can be programmed.
Furthermore the integration of such a programmable control has the advantage that the individual cut lengths can be optimized for a given tube length and with respect to the individual cut-off lengths, so that substantially the complete length of the tube can be utilized. Thus, for example, one or more sleeves of equal length, and toward the end of the tube one or more sleeves with a cut-off length deviating from the first cut-off length, can be cut during one working process, so that up to a respective cut portion at the end of the tube, no, or nearly no, waste can arise.
According to an advantageous embodiment of the invention, it is provided that the cutting knife and the ejector are arranged on a flange which is removably arranged on a slide. A rapid and simple change of the cutting knife can then take place by means of a further unit. Alternatively, it can also be provided that only a rapid change unit of the cutting knife is provided on a holder which in its turn is arranged on the flange. By means of this removable flange, which is preferably arranged by means of quick-acting clamping means, the apparatus can be quickly changed over to cutting tools with and without drive.
According to a further advantageous embodiment of the invention, it is provided that the ejector has a driving element which can travel in the direction toward the counter-holder and which engages with an element on the counter-holder. It can thereby be made possible that, for example when the slide is repositioned from a last cutting position into a starting or null position at the beginning of the tube, an ejection of the cut-off sleeves into a travel path can simultaneously take place. An expensive mechanism which occupies a considerable constructional space is thereby not required in order to strip the cut-off sleeves from the counter-holder. At least two functions, in particular stripping of the sleeves and resetting of the slide into an initial position, can be simultaneously implemented in one movement process.
According to a further advantageous development of the invention, it is provided that a recognition means, preferably a proximity switch, is provided on the flange and is arranged at an acute angle to an end of the tube which abuts a counter-holder. The beginning of the tube can thus be recognized with great accuracy, since in contrast to the otherwise usual arrangements, a reflection of the waves or beams by the counter-holder, falsifying the recognition, can be excluded. It is advantageously provided that the first cut or initial cut after the beginning of the tube has a given distance which can be determined by the data processing equipment. Thus a clean first cut shortly after the beginning of the tube can take place, so that the waste is again small and a high utilization of material can be attained.
According to the invention, further advantageous developments are set forth herein.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment example of the invention is explained in the following examples.
FIG. 1 shows a side view of the apparatus according to the invention,
FIG. 2 shows an end view of the apparatus, from the left according to FIG. 1 , and
FIG. 3 shows an end view of the apparatus, from the left according to FIG. 1 , and
FIG. 4 shows a side view of an another embodiment of the invention without the alternative structure.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a schematic representation of an apparatus 11 for the cutting of tubes 12 , in particular paper or cardboard tubes. Plastic tubes or tubes of further materials can likewise also be cut. The tubes 12 can have different internal diameters. For example, a tube diameter of 20-750 mm can be processed. The wall thickness of the tube 12 can be up to 40 mm, for example.
The tube 12 is received by a counter-holder 13 which is mounted on a base frame 14 of the apparatus 11 . The base frame 14 furthermore receives in the upper section a guide rail 16 , on which a slide 17 is arranged to be displaceable along the counter-holder 13 . A flange 18 can be fastened to the slide 17 and receives a cutting tool 19 , an ejector 21 , and a proximity switch 22 ( FIG. 3 ). The range of movement of the slide 17 includes on the one hand an initial position 23 at the right-hand end of the guide rail 16 and an ejector position 24 at the left-hand end of the guide rail 16 . The distance from the initial position 23 to the ejector position 24 corresponds at least to the length of the counter-holder 13 which is available for the support of a tube 12 .
The guide rail 16 includes a housing in which a threaded spindle 26 is rotatably mounted. The slide 17 has a corresponding guide element (not shown) which engages the threaded spindle 26 . A servomotor or stepping motor 27 is provided at a drive-side end of the threaded spindle 26 , and engages the threaded spindle 26 via a coupling 28 .
The stepping motor 27 is selected such that, for example, a 1:1 transmission can take place from the drive shaft (not shown) of the motor 27 to the threaded spindle 26 , so that precise driving of the slide 17 and thus an exact travel path with respect to the cutting tool 19 can be attained.
It can alternatively be provided that a gear is arranged between the threaded spindle and the motor 27 . It can furthermore be alternatively provided that the slide 17 is driven to travel along the guide rail 16 by means of a toothed belt, a chain, or the like, e.g., the threaded spindle 26 shown in FIG. 1 .
The counter-holder 13 is fixedly or rotatably mounted to a left side of the base frame 14 . At its right-hand free end, an abutment 29 is provided which is pivotably arranged on the guide rail 16 and which receives the free end of the counter-holder 13 during the cutting process. The abutment 29 is pivoted out of its holding position for the loading and unloading of the tube 12 .
In FIG. 1 , a unit 30 is provided on slide 17 , and has a non-rotatingly driven cutting tool 19 . A unit 35 is furthermore shown which has the cutting tool 19 , which is driven by the motor 37 . The ejector 21 is arranged to the left of the cutting tool 19 of the unit 35 . This ejector 21 has a movable bolt 39 . The movable bolt 39 is movable in the direction toward the counter-holder 13 . The ejector 21 is spaced apart from the counter-holder 13 .
A mounting 31 is provided on the flange 18 of the unit 30 , and receives via roller bearings 32 a cutting knife 33 which is freely rotatable. The cutting knife 33 is clamped between two seatings 34 and arranged interchangeably with respect to the mounting 31 . This can be made possible in that one of the seatings 34 is released, or in that the mounting 31 is released, or in that the whole unit 30 , and thus the flange 18 , is removed from the slide 17 .
Alternatively to the freely rotatable arrangement according to the unit 30 , a stationary cutting knife can also be provided. For this, a bolt 36 can be inserted in a bore of the seating 34 , so that the freely rotatable arrangement of the cutting knife 33 is locked.
Furthermore, the unit 35 can alternatively be provided, the cutting tool 33 , in the form of a cutting knife being driven by a motor 37 . One or more units 30 or 35 , which can also be provided in combination, can be selected according to the respective application. The ejector 21 is spaced apart from the units 30 or 53 , as shown in FIG. 1 . The cutting units 30 , 53 and 35 and the ejector 21 are each connected to the threaded spindle 26 by the slide 17 for movement along the guide rail 16 , as shown in the upper portion of FIG. 1 .
The cutting tool 19 can be arranged to be resiliently compliant. During the cutting process, the cutting tool 19 is moved toward the counter-holder 13 , for example, by means of a mechanism, compressed air, pneumatic system, or electric motor, or the like. During the movement, the tube 12 rotating on the counter-holder 13 is cut. After the cutting tool 19 nearly abuts the counter-holder 13 or contacts this, a possible further feed can be compensated by the resiliently compliant arrangement. The life of the cutting tool 19 can thereby be increased. The cutting quality can be thereby increased at the same time, due to the smaller damage to the cutting tool 19 . It can be advantageously provided that the counter-holder 13 is arranged to be insulated with respect to the base frame 14 , so that the cutting tool 19 comes into electrical contact when it strikes, or rests on, the counter-holder 13 , upon which the feed movement or the cutting movement of the cutting tool 19 is immediately stopped. This or a similar kind of electrical monitoring likewise increases the life of the cutting tool 19 .
The proximity switch 22 is arranged on the flange 18 , to the right of the cutting tool 19 in the embodiment example. This is arranged on the flange 18 at an acute angle to an end surface of the tube 12 , so that a scan does not take place perpendicularly from above, and thus parallel to the end surface of the tube 12 , but that the end surface of the tube 12 is used as the reference surface. The beginning of the tube 12 can thereby be determined exactly. The proximity switch 22 can for example be provided as an infrared sensor or the like. Further optoelectronic switches can likewise be used.
The ejector 21 is arranged to the left of the cutting tool 19 of the unit 35 . This ejector 21 is connected to the guide rail 16 through the ejector sleeve 41 and has a movable bolt 39 which is movable in the direction toward the counter-holder 13 or an ejector sleeve 41 . As soon as, for example, the flange 18 has come into an ejector position 24 , the ejector 21 can be driven by means of a relay or by means of a control, as is known in the art, so that the bolt 39 engages in a groove 42 or in a correspondingly formed recess on the bolt 39 . After this is positively arranged in the groove 42 , the slide 17 can be guided over into the initial position 23 , upon which the cut-off sleeve is ejected and is simultaneously guided away via a chute 43 . Immediately before the end of the counter-holder 13 , the bolt 39 is brought back into its initial position, so that the ejector sleeve 41 remains near the free end of the counter-holder 13 , which is brought back into its initial position by loading a new tube 12 onto the counter-holder 13 .
The apparatus 11 furthermore has a programmable data processing equipment and control 44 . The cut-off length of the respective sleeves can be freely programmable by this. Thus, for example, several sleeves of equal or different lengths can be cut from a tube 12 . It can also be provided, according to a program, that an optimizing of cutting is programmable in dependence on the total length of the tube 12 , according to which a number of sleeves with a first cut length, a further number of sleeves with a second cut length, and possibly a further number of sleeves with one or more further cut lengths are cut, in order to make the cutting waste as small as possible. During the stripping phase of the sleeves, a positioning of different goods baskets under the chute 43 can take place, corresponding to the movement of the slide 17 from the ejector position 24 into the initial position 23 , so that a sorting of the different cut lengths can take place simultaneously with the stripping.
Furthermore, the distance of the first cut from the beginning of the tube 12 can be set by this data processing equipment. This cut can be situated immediately after the beginning of the tube 12 , or for example one or two centimeters behind it.
Alternatively, two or more slides 17 can be provided on the guide rail 16 , arranged at a given distance from each other, whereby a cut optimization can take place by means of the program control to the effect that, for example with three slides with cutting tools 19 arranged on them, the cutting time of the whole tube can be reduced to a third. Furthermore, it can be alternatively provided that two or more guide rails are provided to a counter-holder, so that on each guide rail respectively one or more cutting tools 19 can follow, independently of the cutting tool or tools 19 , on the further guide rail or rails. In particular, with very long tubes, such an arrangement can lead to a reduction of cycle times. The individual cutting processes can be coordinated by a common control, so that a frictionless cutting of the sleeves into the respectively required lengths can take place.
The tube 12 is held in a defined position during a cutting process by guide rollers 46 arranged to left and right of the counter-holder 13 , as is shown, for example, in FIG. 2 . The guide rollers 46 engage such that they hold the tube 12 down on the counter-holder 13 . The counter-holder 13 is advantageously made small in comparison with the tube diameter of the tube 12 , so that the latter is freely supported on the counter-holder 13 . It can likewise be provided, for example with a small diameter of the tube 12 , that the counter-holder corresponds approximately to the internal diameter of the tube 12 . In this case of application, the guide rollers 46 have a supporting action, in particularly so that the counter-holder is supported when it receives the cutting force. The guide rollers 46 can, for example, be arranged in a ten o'clock or two o'clock position. The guide rollers 46 advantageously extend almost over the whole length of the counter-holder 13 . At least one of the two guide rollers 46 , or advantageously both guide rollers, are driven, in order to set the tube 12 in rotation. In FIG. 2 , the drive for the guide rollers 46 by belts or chains or the like is represented, a gearwheel drive 47 being illustrated which makes it possible for both the left and the right guide rollers 46 to have the same drive speed. The guide rollers 46 are received on supporting arms 48 , which are respectively mounted for pivoting around a shaft 49 by means of a power element 51 which is preferably driven by compressed air. The synchronous movement of the supporting arms 48 during the advance movement is made possible by the gearwheel pair 52 according to FIG. 3 . The power element 51 can be driven either electrically or pneumatically. The use of compressed air has the advantage that on exceeding a given operating pressure a further feed movement of deflection of the supporting arms 48 is prevented, so that it can be ensured that the guide rollers 46 rest on the tube 12 with a minimum pressure and also drive it in rotation. The guide rollers 46 are advantageously hinged on the supporting arms 48 so that a fine adjustment to different diameters of the tube 12 can take place; it is advantageously provided that the drive of the guide rollers 46 can remain the same, independently of the fine adjustment. The compressed air supply and also the drive of the supporting arms 48 is shown schematically in FIG. 1 in the left-hand portion of the base frame 14 .
In FIG. 1 it is furthermore shown as an alternative that the apparatus 11 can also be provided with cutting tools 19 fixed to the guide rail 16 for specific applications, as is shown, for example, by the unit 53 . Such a unit 53 can be additionally provided, for example between two movable slides 17 , or instead of displaceable slide 17 .
It can furthermore be alternatively provided that the ejector 21 engages with a movable bolt or the like directly at the end of a tube 12 in order to strip the cut sleeves from the counter-holder 13 without an ejector portion 41 being provided. Likewise, instead of the ejector 21 , the cutting knife could take over the stripping function.
A feed movement of the cutting tool 19 can likewise be driven by the programmable data processing equipment and control during the cutting process in dependence on the raw material and also on the wall thickness of the tube. The feed speed can likewise be adjusted in dependence on a driven cutting tool 19 .
A complete set of claims currently in this application, with status indicators, is attached hereto.
In FIG. 4 , the apparatus is shown without the alternative structure. | An apparatus for cutting tubes includes a counter holder arranged to receive a tube, having at least one cutting tool that is movable to a cutting position on the counter holder during a cutting process, having an ejector that ejects cut-off portions of the tube, wherein the ejector is movable relative to the counter-holder, having a slide that is movable along the counter-holder on which the at least one cutting tool and the ejector are provided, and having a programmable control for freely setting cut-off lengths of tubular sleeves by moving the cutting tool on the slide. | 8 |
The present invention relates to a ruminant animal feed, and a method of making the same. More specifically, it relates to a method of producing a solid, granular form of calcium ammonium lactate (hereinafter referred to as "CAL").
BACKGROUND OF THE INVENTION
CAL is a crystalline substance which is formed in the manufacture of fermented ammoniated condensed whey (hereinafter referred to as "FACW"). Further information on both CAL and FACW may be obtained from U.S. patent of Juengst et al. U.S. Pat. No. 4,333,956 granted June 8, 1982. The disclosure of that patent relating to these substances is incorporated herein by reference.
Under certain conditions, CAL separates from FACW and crystalline CAL can be collected. However, the CAL collected is in the form of a sediment usually, containing small amounts of FACW. Therefore, it is not a free-flowing powder. The handling of the CAL sediment is therefore difficult, increasing its cost and limiting the ways in which it can be put to use.
SUMMARY OF THE INVENTION
The present invention provides a method for converting CAL sediment, derived from FACW, into a free-flowing solid material. Briefly, the process consists of mixing CAL sediment with calcium sulfate and air drying the mixture.
BRIEF DESCRIPTION OF FIGURES OF DRAWING
In the drawings:
FIG. 1 is a side elevation view of a laboratory apparatus useful for practice of the process of the invention;
FIGS. 2 and 3 are graphs tabulating data with respect to quantities of calcium sulfate to be used in relation to the composition of the feed.
DETAILED DESCRIPTION OF THE INVENTION
The raw material for the practice of the present invention is CAL sediment derived from FACW. Usually the FACW is obtained as a hot liquid after it has been concentrated by evaporating water, using heat. The FACW is cooled to allow formation of CAL crystals to be completed. Then the mixture is decanted, for example in a continuous centrifuge such as the Sharples P-3400 Super-D-Canter. The product should be decanted promptly after the crystals have formed, as the recovery of crystals by decantation is more efficient when the product is fresh. For example, a sample stored for two days gave a higher recovery of CAL solids than a three month old sample. The product obtained at this stage is a semi-dry crystalline material.
The second raw material used in the present invention is calcium sulfate. Preferably, the product is calcium sulfate dihydrate or calcium sulfate hemihydrate. The hemihydrate was found to be somewhat more effective, in that the rate of drying was somewhat higher. For instance, in an experiment with comparable feeds and drying conditions, the hemihydrate produced a dry product in 5-6 minutes whereas the dihydrate required 7-8 minutes. Preferably the salt should be in the form of a granular or finely divided material. Other potential drying materials have been evaluated, including calcium chloride, calcium carbonate, dicalcium phosphate, soluble starch and shredded cellulose, but none was found to be as effective as calcium sulfate.
The amount of calcium sulfate utilized varies in accordance with the nature of the CAL sediment. In general, the amount used is about 2-30% of the total amount of mixture, and it depends upon the amount of FACW in the sediment. The exact amount to be used for a particular CAL sediment can be determined by a simple experiment, using the apparatus illustrated in FIG. 1. Mixtures of the sediment with various amounts of calcium salt are dried in that apparatus or a similar apparatus. Incomplete drying can be detected by adherance of the feed to the walls of the drying vessel. Excessive drying can be detected by a massive buildup of particles on the filter at the exit of the drying vessel, or by fine particles blowing through the filter. In general, acceptable levels for calcium sulfate dihydrate have been found to correspond to the following equations. A minimum amount of calcium sulfate, as the dihydrate, is given by the equation % CaSO 4 =1.12 (100-% CAL)-6. A reasonable maximum is given by the equation % CaSO 4 =1.40 (100-% CAL)- 6.
More detailed information on the appropriate amount of calcium sulfate to be used can be derived from FIGS. 2 and 3. FIG. 2 is a graph recording the results of experiments in which various mixtures were dried. The mixtures contained a sediment which in turn contained 92% CAL (balance FACW). This sediment was then mixed with various amounts of decanted FACW to provide mixtures for drying. Across the top of the graph the percentage of CAL sediment (containing 92% CAL) is indicated whereas across the bottom of the graph the corresponding amounts of FACW added to the mixtures are indicated. On the vertical axes, the percentages of calcium sulfate dihydrate mixed with the sediment/FACW mixtures is indicated at the left, and at the right there is given the percentage of the sediment-FACW mixture which was combined with the calcium sulfate. The two lines plotted along the graph indicate upper and lower limits on the amount of calcium sulfate found to be acceptable. The amounts of calcium sulfate corresponding to the area between the lines gave acceptable drying. Higher amounts, indicated by the area below the lines in the graph, gave excessive dusting whereas smaller amounts of calcium sulfate caused the material to adhere excessively to the drying vessel.
FIG. 3 is another graph, based upon the same experiments. In this case, the horizontal axis indicates the proportion of CAL and FACW (in total) and the vertical axis indicates the proportion of sediment and calcium sulfate in the mixtures which were dried. The hatched area in the center of the graph indicates appropriate amounts of calcium sulfate to be used, in accordance with the composition of the material being dried.
Various forms of apparatus can be used to dry the mixtures of CAL sediment and calcium sulfate. For example, a fluidized bed or other conventional air drying equipment may be used. The product may also be dried to simply spreading it out on a flat surface and letting it stand, for example overnight.
The air used to dry the apparatus is conveniently at room temperature. Temperatures up to 30° C., or a little higher, have been found to be satisfactory. At temperatures of 40° C. or above, it was found that the product tended to form into clumps and not dry evenly.
A suitable laboratory apparatus for carrying out the invention is illustrated in FIG. 1. This apparatus was found to be suitable for drying 25 gram quantities of sediment. In the Figure, reference numeral 1 indicates a 500 ml Erlenmeyer flask having an air inlet tube 2 extending horizontally through the lower portion of the side of the flask. At the inner end of the air inlet tube 2, the tube is bent downwardly and narrowed to give a 2 mm diameter orifice 3. The top of the flask is sealed by a rubber stopper 4, and an exit tube 5 is inserted through the stopper, having an internal diameter of 10 mm and a height of 200 mm. At the upper end of the exit tube, there is a fine gauze 6 covering the exit, held in place by a rubberband 7. A thermometer 8 also is inserted through the rubber stopper 4, to observe the temperature of the air flowing through the flask. The numeral 9 indicates the inward flow of air to the flask, at a rate of 12 liters per minute. The arrows 10 indicate the air flow through the flask and the arrows 11 indicate the circulation of the sediment as it is being dried.
In a series of experiments, 25 gram samples of CAL sediment were mixed with various potential drying agents, and the results of the experiments are recorded in Table 1. In this case, the sediment contained 93% CAL and 7% FACW liquid. The drying air was at 23° C. The flask was weighed as the experiment continued, for 10 minutes, to determine the amount of liquid which had been removed by evaporation, and this is recorded as the percentage of mass lost in Table 1.
TABLE 1______________________________________Percent of Mixture Evaporated %Drying Drying MinutesAgents Agent 1 2 3 4 5 6 7 8 9 10______________________________________Calcium 0 1.6 2.4 3.2 3.6 3.6 4.0 3.6 4.4 4.4 4.8Chloride 2 1.2 2.0 2.8 3.6 4.0 4.4 4.4 4.8 4.8 4.8Dihydrate 4 1.2 2.0 2.4 2.8 3.2 3.6 4.0 4.0 4.0 4.4 6 1.6 2.0 2.4 3.2 4.0 4.0 4.0 4.4 4.4 4.4 8 0.8 1.6 2.4 2.8 2.8 3.2 3.6 3.6 3.6 3.6Calcium 0 0.8 1.2 2.0 2.4 2.8 2.8 3.2 3.6 3.6 4.0Sulfate 2 0.8 1.6 2.0 2.8 3.6 4.0 4.4 4.4 4.4 4.4Dihydrate 4 2.0 2.4 3.6 4.4 4.8 5.2 5.2 5.2 5.6 5.6 6 1.2 2.0 3.2 4.0 4.4 4.8 5.2 5.6 5.6 5.6 8 1.6 2.4 3.2 4.0 4.4 4.8 5.2 5.6 5.6 6.0Calcium 0 0.8 1.6 2.0 2.4 2.8 3.2 3.2 3.6 4.0 4.0Carbonate 2 1.2 1.8 2.4 3.2 3.6 4.0 4.2 4.4 4.8 4.8 4 1.2 1.8 2.4 2.8 3.6 4.0 4.2 4.4 4.4 4.4 6 0.8 1.6 2.8 3.2 3.6 4.0 4.4 4.6 4.6 4.8 8 0.8 1.6 2.2 2.8 3.2 3.6 3.6 4.4 4.8 4.8Dicalcium 0 0.8 1.4 1.8 2.2 2.8 3.0 3.4 3.6 4.0 4.0Phosphate 2 0.8 1.4 1.8 2.2 2.8 3.0 3.4 3.4 3.8 3.8 4 1.0 1.6 1.8 2.2 2.8 3.0 3.4 3.6 3.6 4.0 6 1.0 1.6 2.0 2.4 2.8 3.0 3.4 3.4 3.6 3.8 8 0.8 1.4 2.0 2.4 2.8 3.2 3.2 3.6 3.8 4.0Soluble 0 0.8 1.4 1.8 2.2 2.8 3.0 3.4 3.6 4.0 4.0Starch 2 1.2 2.0 2.4 2.8 3.2 3.6 4.0 4.0 4.0 4.2Powder 4 1.2 1.2 2.0 2.4 3.0 3.2 3.6 4.0 4.0 4.0 6 1.2 1.8 2.6 3.2 3.4 4.4 4.6 4.8 4.8 5.2 8 1.2 1.8 2.4 3.2 3.8 4.0 4.8 4.8 5.2 5.2Cellulose 0 0.8 1.6 2.2 2.6 3.2 3.2 3.6 3.8 4.0 4.0 2 0.8 1.0 2.4 3.2 3.6 3.6 3.8 4.2 4.4 4.8 4 1.2 1.8 2.6 3.0 3.4 3.8 4.0 4.2 4.6 4.6 6 1.0 1.8 2.6 3.4 3.6 3.8 4.0 4.0 4.4 4.6 8 1.2 2.0 2.4 3.2 3.4 3.6 3.8 3.8 4.4 4.6______________________________________
The properties of the sediment obtained after 10 minutes of air drying and 23° C. is given in Table 2.
TABLE 2__________________________________________________________________________ PROPERTIES OF DRIED SEDIMENT PRODUCTSProperties of Sediment ProductsAfter 10 Minutes of Air Drying at 23° C. Contained Percent Sticky Compacted Adhered Smelled Dust orDrying Drying To The Under To Drying Balled of PowderAgent Agent Touch Pressure Vessel Excessively Ammonia Particles__________________________________________________________________________Calcium 0 + + + - - -Chloride 2 + + + - - -Dihydrate 4 + - + + - - 6 - - - + - - 8 - - - + - +Calcium 0 + + + - - -Sulfate 2 + + + - - -Dihydrate 4 - - - - - - 6 - - - - - - 8 - - - - - +Calcium 0 + + + - - -Carbonate 2 + + + - + - 4 + + + - + - 6 + + - - + - 8 - + - - + -Dicalcium 0 + + + - - -Phosphate 2 + + + - - - 4 + + + - - - 6 + + + - - - 8 + + + - - -Soluble 0 + + + - - -Starch 2 + + + - - -Powder 4 + + + - - - 6 + + + - - - 8 + + + - - -Cellulose 0 + + + - - - 2 + + + - - - 4 + + + - - - 6 + + + - - - 8 + + + - - -__________________________________________________________________________
The composition of the product obtained using 4% calcium sulfate in the foregoing experiment is as follows:
______________________________________Constituent Percent______________________________________Solids 98 Est.Total Nitrogen 6.18 (38.6% CPE)Ammonia Nitrogen 5.95 (37.2% CPE from NPN)Lactic Acid 60.2Calcium 7.98Sulfur 0.57 Est.______________________________________
The product is useful as a nitrogen supplement for ruminant animals on high energy rations. The following is a brief description of a trial which was conducted using CAL sediment, that is the raw material used in accordance with the present invention. The product of the present invention can be used in essentially the same way, making an appropriate adjustment for the amount of sulfur introduced with the CAL.
Composition of CAL used in the trial was 8.6% Ca, 6.3% N, 74.4% lactic acid and 11.1% water. To determine the palatability of the benefit derived from supplementing corn silage with CAL, two trials were conducted. In trial 1, 18 steers (9 per pen) were fed increasing levels of CAL, (0.36, 0.40, 0.46, 0.50, 76 and 1.01 kg) in complete rations. For an additional 2 days, steers were offered CAL free choice separate from the complete ration. In trial 2, 32 steers (1 per pen) were fed cornsilage ad libitum and 1% of their dry matter as ground corn. Two of the pens received a negative control ration (9% CP) and the other two were supplemented with CAL to raise CP to 12%. When CAL was mixed in the complete ration in trial 1, total dry matter intakes were increased 12.3% from raising CAL intake from 0.36 to 0.46 kg; but they were markedly depressed at 1.01 kg per day. However, when CAL was offered free choice, steers ate 1.07 kg per day and total dry matter intakes were 30% higher than when CAL was added in the complete ration at 1.01 kg per day. In trial 2, daily feed intakes (kg/day) were slightly lower for the ration supplemented with CAL, but average daily gains exceeded the negative control group by 33.5% (0.93 vs 1.26 kg). Less feed was also required per unit gain when CAL was fed (6.34 vs 4.54). These results show that CAL can be effectively utilized as a nitrogen supplement for ruminants on high energy rations. Moreover, the material was palatable when fed free choice.
The foregoing description includes several specific embodiments. However, no limitation thereto is intended, the full scope of the invention being defined in the appended claims. | A process of producing a ruminant animal feed by mixing calcium ammonium lactate sediment derived by precipitation from fermented ammoniated condensed whey, with calcium sulfate and drying the mixture in contact with air. | 0 |
FIELD OF THE INVENTION
[0001] The subject of the present invention is a canned or sleeved rotary machine equipped with a rotor in contact with a particle-laden, acidic or corrosive liquid or gaseous atmosphere and the invention relates more specifically to a rotary machine equipped with sleeved magnetic bearings, with sleeved detectors for magnetic bearings and/or with a canned electric motor.
[0002] The invention also relates to a method of manufacturing such a machine.
PRIOR ART
[0003] FIG. 3 depicts an example of a sleeved radial magnetic bearing which comprises a rotor armature 6 secured to a rotor 1 in contact with an aggressive atmosphere, and a stator armature 4 secured to a stationary support 2 , the stator armature 4 , which comprises one or more windings 42 and a ferromagnetic body 41 , being positioned in a protective metal enclosure comprising a solid part secured to the stationary support 2 or coincident therewith, a thin can or sleeve 3 and a hermetic passage 8 for wiring 8 a supplying the windings 42 . The thin can or sleeve 3 of thickness e 0 is situated a distance Δ from the rotor armature 6 in order to define the air gap of the magnetic bearing.
[0004] A potting compound 7 fills almost all of the internal voids left in the ferromagnetic body 41 , the windings 42 and the wiring 8 a so that the thin can or sleeve 3 can rest against a flat or cylindrical surface when the bearing or its associated detector is placed in a pressurized environment.
[0005] FIG. 4 similarly shows an example of a sleeved axial magnetic bearing which comprises a rotor armature 106 in the form of a disk fixed at right angles to the axis of a rotor 101 in contact with an aggressive atmosphere, and a stator armature 104 secured to a stationary support 102 . The stator armature 104 comprises windings 142 , 143 and a ferromagnetic body 141 , which are placed in a protective metal enclosure comprising a solid part secured to the stationary support 102 or coincident therewith, a thin can or sleeve 103 and a hermetic passage 108 for wiring 108 a supplying the windings 141 , 142 . An air gap of magnitude Δ is defined between the rotor armature 106 and the thin can or sleeve 103 of thickness e 0 .
[0006] As in the case of the sleeved radial magnetic bearing of FIG. 3 , a potting compound 107 fills almost all of the internal voids left in the ferromagnetic body 141 , the coils 142 , 143 and the wiring 108 a so that the thin can or sleeve 103 can rest against a flat or cylindrical surface when the bearing or its associated detector is placed in a pressurized environment.
[0007] In the case of the known magnetic bearings of FIGS. 3 and 4 , whatever the technology employed, it is very difficult to guarantee that, on the one hand, the protective enclosure will be perfectly filled or, on the other hand, that this same enclosure will be perfectly hermetic. The overall leak rates generally observed are of the order of 1×10 −8 mbar·l/s (rate measured under helium at 1 bar gauge).
[0008] The sleeved bearing assembly is intended to be positioned in a gaseous environment at a variable pressure that fluctuates with the treatment process (typically from 1 to 200 bar).
[0009] The protective enclosure consists of the armatures 2 , 3 , 8 or 102 , 103 , 108 . Because the armature consisting of the can or sleeve 3 or 103 has a thickness (e 0 ) of the order of 0.5 to 1 mm, an internal pressure of the enclosure that is raised by comparison with the external pressure may be enough to deform the can or sleeve 3 or 103 to such an extent that the air gap (Δ) typically measuring 0.5 to 1 mm disappears, leading to destruction of the can sleeve 3 or 103 though contact with the rotor armature 6 or 106 facing it.
[0010] It is thus possible to calculate that, with the aforementioned leak rate of 1×10 −8 mbar·l/s, a volume of 1 cm 3 placed in a gas at 100 bar above the internal pressure of the enclosure 2 , 3 , 8 , or 102 , 103 , 108 , respectively, increases in pressure by 1 bar in about 12 days.
[0011] It should be noted that when use is made of a very thin and wide can or sleeve 3 , 103 , as is notably the case for a sleeve 103 of an axial bearing, the slightest raised internal pressure deforms the sleeve, this deformation being elastic deformation first of all, then plastic deformation.
[0012] Considering the example of an axial thrust bearing with a diameter of 450 mm, fitted with a sleeve 103 with a thickness of 0.5 mm, it can be calculated that an increase in pressure of 0.1 bar is enough to cause the sleeve 103 to deflect by 1 mm, thus filling the air gap (Δ). This pressure rises to 0.6 bar if the sleeve has a thickness of 1 mm. A raised pressure of some intermediate value gives a deflection of some intermediate magnitude.
[0013] In the case of sleeved bearings of the prior art, the protective enclosure is closed under atmospheric conditions and the residuals gaps internal to the enclosure have a high oxygen content. Because sleeved bearings are generally used in a natural gas (CH 4 ) environment, the leaks create a potentially explosive environment inside the enclosure.
[0014] In any event, the raised internal pressure in excess of atmospheric pressure created inside an enclosure as a result of the accumulation of leaks over time will, in the event of depressurization, cause the can or sleeve to deform to an extent that may go so far as to fill the air gap Δ and damage the bearing.
DEFINITION AND SUBJECT MATTER OF THE INVENTION
[0015] It is an object of the present invention to remedy the aforementioned disadvantages and, in particular, to tolerate, in a canned or sleeved assembly for a rotary machine, such as a sleeved radial or axial magnetic bearing, a sleeved detector associated with such a bearing and/or a canned electric motor, an increase in internal pressure due to leakages with no risk of deformation in the event of depressurization of the environment in which it is positioned, to thus considerably increase the service intervals and to guarantee that an explosive mixture cannot be stored.
[0016] These objects are achieved, according to the invention, by virtue of a canned or sleeved rotary machine equipped with a rotor in contact with a particle-laden, acidic or corrosive liquid or gaseous atmosphere, and with a functional electrical assembly comprising a rotor armature secured to the rotor and placed in said gaseous atmosphere and a stator armature secured to a stationary support and positioned facing said rotor armature, the stator armature comprising at least one winding and a ferromagnetic body which are positioned in a protective metal enclosure comprising a solid part secured to the stationary support or coincident therewith, a thin can or sleeve and a hermetic passage for wiring supplying said windings, a potting compound filling residual internal gaps left in the ferromagnetic body, the windings and the wiring, wherein a dead volume in which the pressure is below atmospheric pressure is created inside the protective metal enclosure.
[0017] The dead volume is preferably formed behind the hermetic passage.
[0018] More particularly, the protective metal enclosure comprises a drilling so that the vacuum can be created in said dead volume and a blanking plug welded in position to plug said drilling while at the same time maintaining the vacuum.
[0019] The dead volume may have a capacity in excess of 100 cm 3 and even of the order of several hundred cm 3 .
[0020] The thin can or sleeve has a thickness of between 0.3 and 2 mm, and preferably of between 0.4 and 1 mm.
[0021] The air gap Δ between the rotor armature and the stator armature may preferably be between 0.4 and 3 mm.
[0022] The invention applies equally well to a radial bearing as to an axial bearing the stator armature of which collaborates with a rotor armature in the form of a disk perpendicular to the rotor.
[0023] The thin can or sleeve may, for example, be made of stainless steel of the 17-4 PH, 316L or 904L type or of inconel.
[0024] Another subject of the invention is a method of manufacturing a canned or sleeved rotary machine equipped with a rotor in contact with a particle-laden, acidic or corrosive liquid or gaseous atmosphere and a functional electrical assembly, comprising the steps that consist in forming a rotor armature and securing it to the rotor, forming, facing said rotor armature, a stator armature comprising at least one winding and a ferromagnetic body which are positioned in a protective metal enclosure comprising a solid part secured to the stationary support or coincident therewith, a thin can or sleeve and a hermetic passage for wiring supplying said windings, and in injecting into said protective metal enclosure a potting compound that fills the residual gaps left in the ferromagnetic body, the windings and the wiring, wherein a dead volume in which the pressure is below atmospheric pressure is created inside the protective metal enclosure.
[0025] More particularly, a drilling which opens into the dead volume is formed in the protective metal enclosure and a blanking plug that plugs the drilling is welded, for example by electron bombardment, into position while at the same time maintaining the vacuum.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Other features and advantages of the invention will emerge from reading the following description of some particular embodiments of the invention which are given by way of examples with reference to the attached drawings, in which:
[0027] FIG. 1 is an axial half section of one embodiment of a sleeved radial magnetic bearing according to the invention;
[0028] FIG. 2 is an axial half section of one embodiment of a sleeved axial magnetic bearing according to the invention,
[0029] FIG. 3 is an axial half section of one example of a sleeved radial magnetic bearing according to the prior art, and
[0030] FIG. 4 is an axial half section of one example of a sleeved axial magnetic bearing according to the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] FIGS. 1 and 2 show examples of sleeved magnetic bearings according to the invention.
[0032] Elements that are common to the sleeved radial magnetic bearing of FIG. 1 and the known sleeved radial magnetic bearing of FIG. 3 bear the same reference numerals and will not be described again.
[0033] Likewise, elements common to the sleeved axial magnetic bearing of FIG. 2 and the known sleeved axial bearing of FIG. 4 bear the same reference numerals and will not be described again.
[0034] According to the invention, a dead volume 9 ( FIG. 1 ), or 109 ( FIG. 2 ), in which the pressure is below atmospheric pressure, is created inside the protective metal casing 2 , 3 , 8 , or 102 , 103 , 108 , respectively. The dead volume 9 , or 109 , is formed behind the hermetic passage 8 , or 108 , provided for the wiring 8 a , or 108 a , that supplies the windings 42 , or 142 , 143 , respectively. The potting compound 7 , or 107 , thus fills the residual gaps left in the ferromagnetic body 41 , or 141 , the windings 42 , or 142 , 143 , and the wiring 8 a , 108 a , respectively, but a dead volume 9 , or 109 , is left near the hermetic passage 8 , 108 , respectively.
[0035] The dead volume 9 , or 109 , may have a capacity of a few hundreds of cm 3 , for example between 100 and 400 cm 3 , or may even have a higher capacity depending on the size of the rotary machine.
[0036] Furthermore, according to an important aspect of the present invention, the bearing is closed off maintaining the vacuum.
[0037] Thus, according to the invention, the radial or axial sleeved magnetic bearing is filled with a potting compound 7 , or 107 , leaving a vacuum 9 , or 109 , behind the hermetic passage 8 , or 108 , through which the wires 8 a , or 108 a are respectively led out.
[0038] A drilling 2 b , or 102 b , formed in the protective metal enclosure 2 , 3 , 8 , or 102 , 103 , 108 , respectively, allows access to be had to the dead volume 9 , or 109 , respectively, so that the vacuum can be created. The hermetic sealing of the whole can be tested under helium using this access 2 b , or 102 b , respectively.
[0039] A blanking plug 2 a , or 102 a , is then welded into position, maintaining the vacuum, for example using electron bombardment, in order to plug the drilling 2 b , or 102 b , respectively.
[0040] The dead volume 9 , or 109 , created in the bearing allows gas to be stored only through leaks in the walls, the welds, or the means of electrical connection that make up the protective metal enclosure of the bearing.
[0041] The dead volume 9 , or 109 , is designed to be large enough that leaks can be stored therein without leading to a raised pressure that might deform or damage the can or sleeve 3 , or 103 , respectively, in the event of depressurization. The can or sleeve 103 is particularly sensitive in the case of an axial bearing because the can or sleeve 103 is then very thin and wide.
[0042] Typically, a can or sleeve 3 , or 103 , respectively, has a thickness e 0 of between 0.3 and 2 mm and preferably of between 0.4 and 1 mm, which is of the same order of magnitude as an air gap Δ defined between the rotor armature 6 , or 106 , and the stator armature 4 , or 104 , respectively.
[0043] The can or sleeve 3 , 103 may, in particular, be made of magnetic stainless steel of the 17-4 PH type or of non-magnetic stainless steel 316L or 904L or alternatively may be made of inconel, although these materials are nonlimiting.
[0044] The addition of a dead volume 9 , or 109 , makes it possible to increase the life as a function of the pressure of the enclosure. Thus, a dead volume of 100 cm 3 for an enclosure allowing a raised internal pressure of 1 bar makes it possible, in the event of a leak rate of 1×10 −8 mbar·l/s, and operating at 100 bar, to obtain a run of 1200 days, namely about 3 years, before having to consider servicing during which the enclosure is removed, opened in order to withdraw the gas that has been stored therein through leakages, and reclosed. By contrast, during these 1200 days, the internal pressure will not have stopped rising and will therefore be higher than atmospheric pressure if a vacuum has not been created beforehand. In the event of depressurization, a deformation will be remarked which may go so far as to eliminate the air gap (Δ) if a vacuum has not been created from the outset in the dead volume 9 , or 109 , respectively.
[0045] When, as according to the present invention, a dead volume of a few hundred cm 3 is created in the sleeved bearing enclosure with the bearing closed off while maintaining the vacuum, there is no longer any risk of damage to the bearing for a very long time in the event of depressurization.
[0046] In particular, any gas migrating into the enclosure as a result of leaks will be unable to create an explosive atmosphere because of the absence of oxygen.
[0047] There is an internal-pressure zone of between 0 and 1 bar absolute in which whatever the external pressure higher than 1 bar absolute there will be no deformation of the thin chamber 3 , or 103 , respectively, because the external pressure always keeps it pressed against the core 41 , 141 , respectively.
[0048] The life or preventive maintenance or service interval is increased very significantly.
[0049] Thus, in the example of an axial thrust bearing with a diameter of 450 mm fitted with a sleeve 103 with a thickness of 0.5 mm, manufactured with a created internal volume of 200 cm 3 , but which has not been closed under vacuum, it takes 240 days (about 8 months) for an internal pressure that becomes dangerous (or even catastrophic) in the event of depressurization to be reached (0.1 bar, namely 1.1 bar absolute).
[0050] By contrast, if the enclosure has been closed under vacuum and the same internal volume 109 is under vacuum from the outset, this same internal pressure of 1.1 bar will be reached in 2640 days (7.2 years).
[0051] For 2400 days (6.6 years) the internal pressure will be below 1 bar absolute, that is to say that, even if the gaseous atmosphere in which the rotor 101 and the rotor armature 106 are immersed becomes depressurized, the can or sleeve 103 will experience no deformation.
[0052] It is standard practice in the gas industries in which magnetic bearings are used (compressors, turbo-expanders) for preventive maintenance to be carried out every 5 years. During this maintenance, the emptying and re-evacuating of the enclosure may be envisioned. Such a design involving introducing an evacuated dead volume therefore meets this requirement well.
[0053] It will be noted that the invention applies to radial and axial sleeved magnetic bearings, to canned electric motors, whether or not the motor can is made of metal or nonmetal, and likewise to sleeved magnetic bearing assemblies associated with sleeved detectors of the inductive type or even with axial or radial sleeved detectors of the inductive type considered in isolation and each comprising a rotor armature secured to the rotor and a stator armature comprising a ferromagnetic core and windings, which stator armature is positioned in a protective metal enclosure comprising, as in the case of the magnetic bearings proper, a solid part secured to the ferromagnetic body or coinciding therewith, a thin can or sleeve and a hermetic passage for wires supplying the windings of the stator armature. In this case, as in the case of magnetic bearings proper, a potting compound does not occupy all the residual gaps left empty inside the protective metal enclosure but rather a dead volume in which the pressure is below atmospheric pressure is created inside the protective metal enclosure.
[0054] However, because the detectors each occupy a smaller volume than an associated magnetic bearing, the dead volume formed near the hermetic passage and in which a vacuum has been created through a drilling later plugged by a blanking plug welded into position maintaining the vacuum, may have a reduced capacity of between 50 and 150 cm 3 for example.
[0055] Various modifications and additions may be incorporated into the embodiments described, without departing from the scope of the invention.
[0056] Thus, during the method of manufacturing a rotary machine according to the invention, it is possible for this machine to be subjected to a thermal cycle or to some other treatment that will detach the potting compound 7 , or 107 , from the surfaces of the enclosure 2 , 3 , 8 , or 102 , 103 , 108 , respectively, so that any part situated near the can or sleeve 3 or 103 , respectively, will be in communication in terms of pressure with the dead volume 9 , or 109 , respectively. | A canned or sleeved rotary machine is equipped with a rotor ( 101 ) in contact with a particle-laden, acidic or corrosive gaseous atmosphere, and with a functional electrical assembly such as a magnetic bearing comprising a rotor armature ( 106 ) secured to the rotor ( 101 ) and placed in the gaseous atmosphere and a stator armature ( 104 ) secured to a stationary support ( 102 ) and positioned facing the rotor armature ( 106 ), the stator armature ( 104 ) comprising at least one winding ( 142, 143 ) and a ferromagnetic body ( 141 ) which are positioned in a protective metal enclosure comprising a solid part secured to the stationary support ( 102 ) or coincident therewith, a thin can or sleeve ( 103 ) and a hermetic passage ( 108 ) for wiring ( 108 a ) supplying the windings ( 142, 143 ). A potting compound ( 107 ) fills residual internal gaps left in the ferromagnetic body ( 141 ), the windings ( 142, 143 ) and the wiring ( 108 a ), and a dead volume ( 109 ) in which the pressure is below atmospheric pressure is created inside the protective metal enclosure ( 102, 103, 108 ). | 5 |
INTRODUCTION
This invention relates to novel xanthone compounds, their preparation and use as a medicament. More particularly this invention is directed to the isolation of the novel xanthone natural product sootepenseone from Dasymaschalon sootepense Craib, Annonaceae, its identification and derivatization, and the use of sootepenseone and its derivatives as anticancer agents.
FIELD OF INVENTION
Cancer is perhaps one of the most active anti-human factor operating in the world today, and efforts are being made all over the scientific world to prevent and eradicate it.
New agents with chemotherapeutic value in the fight against cancer is obviously a medical problem of high importance. But the development of new drugs in the cancer field is a difficult task given that anticancer agents must be lethal to, or incapacitate tumor cells, but they should not cause excessive damage to normal cells. At present the state of knowledge in cancer biology and in medical chemistry does not warrant the designing of new classes of molecules which may be effective antitumor agents. Despite the great progress made in cancer biology, molecular pharmacology, pharmacokinetics, medical chemistry and allied fields, the knowledge sought after, is still elusive.
Since the concept of chemotherapeutic treatment of malignant diseases had come to the forefront during the last decades, plant principles and their derivatives have been intensively investigated by scientists all over the world as new antitumor inhibitors. Examples for important anticancer agents of plant origins are the alkaloids vincaleukoblastine (vinblastine) and leurocristine (vincristine), both isolated from Catharanthus roseus . A comprehensive review on natural products as anticancer agents is given by Shradha Sinha and Audha Jain, in: Progess in Drug Research, Vol. 42, pages 53-132 (1994) Basel (Switzerland).
SUMMARY OF INVENTION
In accordance with the present invention there are provided novel cytotoxic xanthone compounds of the general formula (I)
wherein
R 1 is a hydrogen atom; a methyl group (—CH 3 ), a C 2 -C 6 alkyl residue, a formyl group (—CHO); an acetyl residue (—COCH 3 ), —CO—C 2-6 -alkyl, CO—C 3-8 -cycloalkyl, —CO—C 6-18 -aryl or —CO—C 7-24 -aralkyl residue each having optionally one or more substituents selected from the group consisting of —OH, —SH, —NH 2 , —NHC 1-6 -alkyl, —N(C 1-6 -alkyl) 2 , —NHC 6-14 -aryl, —N(C 6-14 -aryl) 2 , —N(C 1-6 -alkyl)(C 6-14 -aryl), —NHCOR 2 , —NO 2 , —CN, —(CO)R 3 , —(CS)R 4 , —F, —CI, —Br, —I, —O—C 1-6 -alkyl, —O—C 6-14 -aryl, —O—(CO)R 5 , —S—C 1-6 -alkyl, —S—C 6-14 -aryl, —SOR 6 , and —SO2R 7 , wherein R 2 to R 7 stands independently of each other for a hydrogen atom, —C 1-6 -alkyl, —O—C 1-6 -alkyl, —O—C 6-14 -aryl, —NH 2 , —NHC 1-6 -alkyl, —N(C 1-6 -alkyl) 2 , —NHC 6-14 -aryl, —N(C 6-14 -aryl) 2 , —N(C 1-6 -alkyl)(C 6-14 -aryl), —S—C 1-6 -alkyl, —S—C 6-14 -aryl residue;
a —COO—C 1-6 -alkyl residue having optionally one or more substituents selected from the group consisting of —OH, —SH, —NH 2 , —NHC 1-6 -alkyl, —N(C 1-6 -alkyl) 2 , —NHC 6-14 -aryl, —N(C 6-14 -aryl) 2 , —N(C 1-6 -alkyl)(C 6-14 -aryl), —NHCOR 8 , —NO 2 , —CN, —(CO)R 9 , —(CS)R 10 , —F, —CI, —Br, —I, —O—C 1-6 -alkyl, —O—C 6-14 -aryl, —O—(CO)R 11 , —S—C 1-6 -alkyl, —S—C 6-14 -aryl, —SOR 12 , and —SO2R 13 , wherein R 8 to R 13 stands independently of each other for a hydrogen atom, —C 1-6 -alkyl, —O—C 1-6 -alkyl, —O—C 6-14 -aryl, —NH2, —NHC 1-6 -alkyl, —N(C 1-6 -alkyl) 2 , —NHC 6-14 -aryl, —N(C 6-14 -aryl) 2 , —N(C 1-6 -alkyl)(C 6-14 -aryl) —S—C 1-6 -alkyl, —S—C 6-14 -aryl residue;
a —CONR 14 R 15 residue wherein R 14 and R 15 stand independently of each other for a hydrogen atom, —C 1-6 -alkyl, —O—C 1-6 -alkyl, —O—C 6-14 -aryl, —NH2, —NHC 1-6 -alkyl, N(C 1-6 -alkyl) 2 , —NHC 6-14 -aryl, —N(C 6-14 -aryl) 2 , —N(C 1-6 -alkyl)(C 6-14 -aryl), —S—C 6-14 -aryl residue;
or a counter cation selected from the group consisting of an alkali or earth alkali metal such as Li, Na, K, Ca, Mg, NR 16 R 17 R 18 R 19 (+) wherein R 16 to R 19 stands independently of each other for a hydrogen atom or a C 1 -C 6 -alkyl residue;
R 2 and R 3 either form part of the C 17 ═C 18 -double bond or are each hydrogen, or a tautomer, an enantiomer, an stereoisomer or a physiologically acceptable salt or a solvate thereof or mixtures thereof.
In the case of a compound according to formula 1 above in the form of a phenolate with a di- or multivalent counter cation, the remaining positive charge can be compensated by association with a physiologically acceptable anion such as CI- or OH-.
The novel compound according to formula I, wherein R 1 is a hydrogen atom and R 2 and R3 form part of the C 17 -C 18 -double bound, has been given the name sootepenseone (1).
According to another aspect of the invention there is provided a process for manufacturing a compound according to formula I by isolation of sootepenseone (1) from the leaves of Dasymaschalon sootepenseone Craib, Annonaceae and its subsequent derivatization.
The present invention further provides the use of the compounds according to formula (I) as medicament, in particular for the treatment of cancer diseases.
The present invention further provides pharmaceutical formulations, comprising an effective amount of a compound according to formula (I) for treating a patient in need thereof. As used herein, an effective amount of a compound according to formula (I) is defined as the amount of the compound which, upon administration to a patient, inhibits growth of tumor cells, kills malignant cells, reduces the volume or size of the tumors or eliminates the tumor entirely in the treated patient.
Thus, the substantially pure compounds in accordance with the invention can be formulated into dosage forms using pharmaceutically acceptable carriers for oral, topical or parenteral administration to patients in need of oncolytic therapy.
In a preferred embodiment, the patient is a mammal, in particular a human.
The effective amount to be administered to a patient is typically based on body surface area, patient weight, and patient condition. The interrelationship of dosages for animals or humans (based on milligrams per meter squared of body surface) is described by Freireich, E. J. et al., Cancer Chemother. Rep., 50 (4) 219 (1966). Body surface area may be approximately determined from patient height and weight (see e.g. Scientific Tables, Geigy Pharmaceuticals, Ardly, N.Y., pages 537-538 (1970)). Preferred dose levels will also depend on the attending physicians assessment of both the nature of the patient's particular cancerous condition and the overall physical condition of the patient. Effective antitumor doses of the present xanthone compounds range from 1 microgram per kilogram to about 5000 micrograms per kilogram of patient body weightmilligram, more preferably between 2 micrograms to about 1000 micrograms per kilogram of patient body weight.
Effective doses will also vary, as recognized by those skilled in the art, dependent on route of administration, excipient usage and the posibility of co-usage with other therapeutic treatments including other anti-tumor agents, and radiation therapy.
The present pharmaceutical formulation may be administered intravenous, intramuscular, intradermal, subcutaneous, intraperitoneally, topical, or intravenous in the form of a liposome.
Examples of dosage forms include aqueous solutions of the active agent, in an isotonic saline, 5% glucose or other well-known pharmaceutically acceptable liquid carrier. Additional solubilizing agents well-known to those familiar with the art can be utilized as pharmaceutical excipients for delivery of the active agent. Alternatively, the present compounds can be chemically modified to enhance water solubility, for example, by formation of pharmaceutically acceptable phenolate salts.
The present compounds can also be formulated into dosage forms for other routes of administration utilizing well-known methods. The pharmaceutical compositions can be formulated, for example, in dosage forms for oral administration in a capsule, a gel seal or a tablet. Capsules may comprise any well-known pharmaceutically acceptable material such as gelatin or cellulose derivatives. Tablets may be formulated in accordance with conventional procedure by compressing mixtures of the active agent and solid carriers, and lubricants well-known to those familiar with the art. Examples of solid carriers include starch, sugar, bentonite. The compounds of the present invention can also be administered in a form of a hard shell tablet or capsule containing for example, lactose or mannitol as a binder and a conventional fillers and tableting agents.
The terms “effective amount” and “effective dose” as referring to the treatment of animals is defined herein to mean those quantities of alkaloid which will cause remession or inhibition of growth of the cancer disease in the animal to which it is administered, without imparting an untolerable toxic response. The effective amount may vary with the way of administration, the administration schedule, the kind of tumor, and other related factors, all of which may be varied without departing from the scope or operativeness of the invention. Generally an effective dose would be one within the range of about 0.001-100.0 mg/kg of body weight/day.
The terms “cancer” or “tumor” as used herein include, but are in no way limited to, adrenocarcinomas, glioblastomas (and other brain tumors), breast, cervical, colorectal, endometrial, gastric, liver, lung (small cell and non-small cell), lymphomas (including non-hodgkin's, Burkitt's, diffuse large cell, follicular and diffuse Hodgkin's), melanoma (metastatic), neuroblastoma, osteogenic sarcoma, ovarian, retinoblastoma, soft tissue sarcomas, testicular and other tumors which respond to chemotherapy.
Other objects and advantages of the invention will become readily apparent from the ensuing description.
DETAILED DESCRIPTION OF THE INVENTION
The inventive compounds according to formula (I) have a pentacyclic xanthone ring system (see for a review: Sultanbawa, M.U.S., Xanthonoids of tropical plants, Tetrahedron 36 (1980) 1465-1506). The following natural compounds are reported as having a similar ring system:
Gambogic acid (2), isolated from Garcinia hanburyi (see Amorosa, M. et al., Ann. Chim. (Rome), 1966, 56, 232; Ahmad, A. S. et al., J. Chem. Soc. (C), 1966, 772 (structure); Arnone, A. et al., Tetr. Lett., 1967, 4201 (pmr data, structure), morellin (3) isolated from Garcinia morella (see: Rao, B. S., J. Chem. Soc, 1937, 853 (isolation); Kartha, G. et al., Tetr. Lett., 1963, 459 (cryst. structure)); Nair, P. M. et al., Indian J. Chem., 1964, 2, 402 (structure)), hanburin (4) isolated from Garcinia hanburyi (see: Asano, J. et al., Phytochemistry, 1996, 41, 815 (isolation, uv, ir, pmr, cmr data) and forbesione (5) isolated from Garcinia forbesii (see: Yuan-Wah eong, Leslie J. Harrison, Graham J. Bennett and Hugh T.-W. Tan, J. Chem. Research (S) 1996, 392-393).
These compounds have at C-5 an isoprenyl side chain in common with a hydrogen bonded phenolic hydroxy group. Morellin (3) and gambogic acid (2) have a chromene ring system in common. All compounds (2) to (5) have in common a bicyclo[2.2.2]octene carbon skeleton fused to a 2,2-dimethyl-tetrahydrofuran ring system (see FIG. 1 ).
However, these compounds show significant structural differences as compared to the compounds according to formula I of the present invention:
1.) the C-5 isoprenyl side chain is oxidized to an aldehyde as in (3) or to a carboxyclic acid as in (2);
2.) the condensed dihydrofuran ring in 3,4-position is missing as in (4) or instead a pyranone ring is present in the 2,3-position as in (3)
3.) the ring system is substituted with an additional isoprenyl side chain at C-5 as in (3) and (5)
By contrast, the compounds of the present invention contain fully substituted dihydrofuran rings except at carbon 2′, fused to the modified xanthone ring system.
For the taxonomy of Dasymaschalon sootepense Craib see V. H. Heywood, “Flowering Plants of the World”, University Press, Oxford, 1978.
Surprisingly, the compounds of the present invention show remarkable antitumor activity. Moreover, the present compounds have a low toxicity.
Thus the xanthone compounds according to the present invention are new and involve an inventive step.
The structures of (2) to (5) are summarized below:
EXAMPLE 1
Isolation of sootepenseone (1; VR-3016, D-25637) from Dasymaschalon sootepense
Plant material has been collected in November 1994 in Doitung, Chiangrai province, northern Thailand. Leaves were air sun dried (about 30-35° C.) for three days and stored in a cloth bag. Dry powdered leaves (6.4 kg) of D. sootepense were sequentially extracted with hexane (110 litre), chloroform (107 litre) and methanol (180 litre) to give the corresponding crude extracts in 204.2, 192.7 and 1187.0 gm, respectively. The crude methanol extract was further partitioned with ethyl acetate(12 litre)-water(4.35 litre) and n-butanol(10 litre)-water to give ethyl acetate, n-butanol and water fractions in 103.6, 388.7 and 401.8 gm, respectively.
The ethyl acetate fraction (100 gm) was chromatographed on silica gel (Merck no. 7734, 1.62 kg, the extract was premixed with 180 g of the silica gel), eluting with mixtures of hexane-ethyl acetate and ethyl acetate-methanol. Fractions (300 ml, each) were combined on the basis of TLC to give a total of 19 fractions (F 1 to F 19 ). Fractions F 7 (1.10 g) and F 8 (0.84 gm) eluting with 7-8% ethyl acetate-hexane, were repeatedly chromatographed on silica gel employing hexane-ethyl acetate as eluting solvents. The fraction eluted with 30% ethyl acetate-hexane gave a light yellow solid which was further purified by radial chromatography (silica gel, 20% ethyl acetate-hexane) and recrystallization from methylene chloride-methanol to give VR-3016 (0.2373 gm). The mother liquor was purified by HPLC (methylene chloride), followed recrystallization in the same solvent to give additional 0.1103 g of VR-3016. The compound has been identified as a new modified xanthone derivative, which has been given the name sootepenseone 1, on the basis of spectral data and single crystal x-ray diffraction analysis.
Physico-chemical data of sootepenseone (1):
m.p. 192-193° C. [α] 28 D−8.00, c=0.075 in CHCI 3 Elemental analysis: Found: C,72.32; H, 6.89. C 28 H 32 O 6 requires: C,72.39, H, 6.94. IR, λ max CHCI 3 cm− 1 : 3560, 3033, 3011, 2980, 2932, 1740, 1638,1590, 1470, 1428,1382. UV, λ max EtOH nm (log e): 213(3.06), 263(2.18), 326(sh)(2.66), 355(2.74). Mass Spectrum: m/z (70eV) 464(2%), 436(100), 421(45), 367(17), 339(60), 297(40), 281(8), 241(7), 215(28), 69(90).
NMR assignments: 1 H and 13 C NMR (300 and 400 Mhz, CDCI 3 ): see separate page
The described isolation procedure is summarized in scheme 1.
Characterization of the Structure of Sootepenseone (1)
The identity of sootepenseone was revealed by analysis of its spectral data i.e. the infrared spectrum, ultraviolet spectrum, mass spectrum and particularly the 1 H n.m.r and 13 C n.m.r spectra.
TABLE 1
1 H-n.m.r. data of sootepensone (1) (δ Units, multiplicities)
long range 1 H-
Protons
13 C-correlation
and
Sootepenseone
(correlated C-
assignments
(1)
atoms)
C2-H
6.05
(s)
C1, C4, C9a
C7-H
3.42
(dd)
C6, C8a, C5*, C2″
C8-H
7.50
(d)
C4b, C6, C7
C1′-H
1.40
(d)
C2′, C3′
C2′-H
4.40
(g)
—
C4′-H
1.18
(s)
C2′, C3′, C4′
C5′-H
1.60
(s)
C2′, C3′, C4′
C1″-CH2
2.27
(dd)
—
C1″-CH2
1.37
(dd)
—
C2″-H
2.45
(d)
C4b, C8a, C1″,
C3″
C4″-H
1.28
(s)
C2″, C3″
C5″-H
1.73
(s)
C2″, C3″
C1′′′-CH2
2.58
(bd)
C4b, C5, C3′′′,
C4′′′
C1′′′-CH2
2.50
(dd)
C4b
C2′′′-H
4.40
(m)
—
C4′′′-H
1.37
(dd)
C2′′′, C3′′′
C5′′′-H
1.10
(dd)
C2′′′, C3′′′
C1-OH
13.10
(s)
C1, C2, C9a
*: suggested correlation
TABLE 2
13 C-n.m.r. data of sootepensone (1) (δ Units, multiplicities)
C-atoms and assignments
Sootepenseone (1)
C1
166.2
(s)
C2
92.6
(s)
C3
168.5
(s)
C4
113.6
(d)
C4a
156.0
(s)
C4b
90.9
(s)
C5
84.6
(s)
C6
203.6
(s)
C7
47.1
(d)
C8
134.1
(d)
C8a
133.7
(s)
C9
178.9
(s)
C9a
101.4
(s)
C1′
13.5
(q)
C2′
91.0
(d)
C3′
43.2
(s)
C4′
21.0
(q)
C5′
23.9
(q)
C1″
26.0
(t)
C2″
49.6
(d)
C3″
82.9
(s)
C4″
28.9
(q)
C5″
30.7
(q)
C1′′′
29.0
(t)
C2′′′
117.8
(d)
C3′′′
135.3
(s)
C4′′′
25.5
(q)
C5′′′
16.9
(q)
Relative Stereochemistry
The relative stereochemistry of sootepenseone (1) has been confirmed by single crystal x-ray diffraction analysis. Hence the absolute configuration is either the stereochemistry as depicted below
or the corresponding enantiomeric form thereof. The relative stereochemistry as depicted above for sootepenseone (1) is also valid for the sootepenseone derivatives according to formula (I), except for those derivatives where inversion or racemization occured under the selected reaction conditions at one or more of the chiral centers at C-5, C-7, C-10a, C-12 and C-22.
Preparation of Derivatives of Sootepenseone
TABLE 3
(I)
Compound No.
R 1
R 2
R 3
1 (Sootepenseone)
H
R2 and R3
forming part of
the C 17 —C 18
double bond
6
acetyl
R2 and R3
forming part of
the C 17 —C 18
double bond
7
a pharmaceutically
R2 and R3
acceptable counter ion*
forming part of
the C 17 —C 18
double bond
8
C 2 -C 20 -alkyl-carbonyl
R2 and R3
forming part of
the C 17 —C 18
double bond
9
methyl
R2 and R3
forming part of
the C 17 —C 18
double bond
10
C 2 -C 20 -alkyl
R2 and R3
forming part of
the C 17 —C 18
double bond
11
benzoyl
R2 and R3
forming part of
the C 17 —C 18
double bond
12
benzoyl substituted with
R2 and R3
—OH or —OCH 3
forming part of
the C 17 —C 18
double bond
13
H
H
H
*suitable counter cations for the phenolat anion are, for example, Na+, K+, ½ Mg++, ½ Ca++, HN(C 1-6 -alkyl) 3 +
Preparation of the compounds 6 to 13 can be accomplished starting from sootepenseone (1) by organic chemistry standard derivatization procedures which are well-known to the person skilled in the art.
EXAMPLE 2
Preparation of 1-O-Acetyl-sootepenseone (6)
A solution of 1 mg of sootepensione (1) in 1 ml anhydrous acetic acid anhydride was stirred at room temperature for 1 h. The solvent was evaporated in a water bath under reduced pressure. Yield: 1 mg of (6) as a crude residue.
For example, salts of sootepenseone (7) can be prepared according to methods and reagents as described in Houben-Weyl, Methoden der Organischen Chemie (methods in organic chemistry), 4th edition 1963, volume 6/2, “Sauerstoffverbindungen I (oxygen compounds I), part 2”, pages 35 ff. So, for example, one eqivalent of a suitable base can be reacted with one equivalent of sootepenseone in a suitable solvent and then evaporating off the solvent or filtrating off the precipitated salt (7). A suitable base, for example, can be selected from the group consisting of alkali or earth alkali hydroxides or an organic amine.
Methylation of the OH-group (compound no. 9) can be accomplished starting from sootepenseone (1) with diazomethan in analogy to the method as described by Mustafa; Hishmat; JOCEAH; J.Org.Chem.; 22; 1957; 1644, 1646.
Acylation of the OH-group (compounds no. 6, 8, 11 and 12) can be accomplished starting from sootepenseone (1) in analogy to the method and reagents as described in Houben-Weyl, Methoden der Organischen Chemie (methods in organic chemistry ), 4th edition 1985, volume E5, “Carbonsäuren und Carbonsäure-Derivate (carboxyclic acids and their derivatives)”, pages 691 ff. Alkylation of the OH-group at C-1 (compound no. 10) can be accomplished starting from sootepenseone (1) in analogy to the standard procedures and by using standard reagents as described in Houben-Weyl, Methoden der Organischen Chemie (methods in organic chemistry), 4th edition, volume VI/3, “Sauerstoffverbindungen (oxygen compounds), part 3”, Georg Thieme Verlag Stuttgart, 1965, pages 49 ff.
Hydrogenation of the isoprenyl C 17 -C 18 double bound to the C 17 —C 17 single bound (wherein R 2 and R 3 in the formula (I) are each a hydrogen atom; compound no. 13) can be performed by standard procedures as described for example in Houben-Weyl, Methoden der Organischen Chemie (methods in organic chemistry ), 4th edition, volume IV/1c, “Reduktion (reduction), part 1”, Georg Thieme Verlag Stuttgart, 1981, pages 15 ff.
Biological Activity
The compound according to the invention are less toxic than the standard compounds (see table 1). On the other hand, sootepenseone (1; D-25637) is more active in the hollow-fiber test as the standard compounds (see table 3).
TABLE 1
Toxicity of sootepenseone (D-25637)
Compound
LD50 (mg/kg i.p. mice)
Sootepenseone (1; D-25637)
>100
Actinomycin D
ca. 1
Vinblastin
ca. 6
Adriamycin
ca. 40
Bleomycin
ca. 80
i.p. intraperitoneal
Discussion of the Results:
Sootepenseone is at least 100 times less toxic than Actinomycin D, about 16 times less toxic than Vinblastin, and 60% and 20% less toxic than Adriamycin resp. Bleomycin.
2. In Vitro Antitumor Activity (XTT proliferation/cytotoxicity test)
The XTT-assay was carried out as described by D. A. Scudiero et al., Cancer Res. 48 (Sep. 1, 1988), pp. 4827-4833. The results of this procedure are expressed as that dose which inhibits growth by 50% as compared to control growth after 45 hours following application of the substance. The dose value as obtained is referred to as ED 50 and activity is indicated for ED 50 levels of ≦30 μg/ml. The smaller the ED 50 level, the more active is the test material. The activities of sootepenseone (1) obtained in Example 1 are reported below in Table 2.
TABLE 2
Compound
Cell line
ED 50 μg/ml
Sootepenseone (1; D-25637)
KB
1.74
L1210
1.74
SK-OV-3
1.74
LNCAP
1.74
Actinomycin D
KB
0.17
L1210
0.17
SK-OV-3
1.74
LNCAP
0.17
Adriamycin
KB
0.17
L1210
0.017
SK-OV-3
0.17
LNCAP
0.17
Bleomycin
KB
0.17
L1210
0.017
SK-OV-3
0.17
LNCAP
0.17
Vinblastin
KB
0.17
L1210
0.017
SK-OV-3
0.17
LNCAP
0.17
KB: epidermal carcinoma of the oral cavity
L1210: mice lymphatic leukemia
LNCaP: lymphoma metastasis of prostate carcinoma
SK-OV-3: human ovarian carcinoma
MCF-7: human breast cancer
Discussion of the Results:
D-25637 has a significant anticancer activity against all tested tumor cell lines.
3. In vivo antitumor activity of sootepenseone (D-25637) (hollow fiber assay)
The hollow-fiber test was carried out as described by Melinda G. Hollingshead et al. in Life Sciences, Vol. 57, No. 2, pp.131-141, 1995. The results are shown in table 3.
TABLE 3
Dose
% Inhibition (cell line)
Compound
(mg/kg)
Location
KB
MCF-7
Sootepenseone
4 × 10 i.p.
s.c.
49
41
(1; D-25637)
Actinomycin D
4 × 0.1 i.p.
s.c.
40
−150
Adriamycin
4 × 4 i.p.
s.c.
52
41
Bleomycin
4 × 8 i.p.
s.c.
53
−67
Vinblastin
4 × 0.65 i.p.
s.c.
13
−165
KB: epidermal carcinoma of the oral cavity
MCF-7: human breast cancer
s.c. subcutaneous
i.p. intraperitoneal
Discussion of the Results:
D-25637 is more active (49% inhibition) against the KB tumor cell line than Vinblastin (13%) and Actinomycin D (40%), and nearly as active as Bleomycin (53%). Moreover, against the MCF-7 cell line D-25637 showed an as strong anticancer activity (41%) as adriamycin, while Actinomycin D, Bleomycin and Vinblastin enhanced tumor growth (negative inhibition values indicate increase in cell growth compared to untreated control group). | This invention relates to novel xanthone compounds, their preparation and use as medicament. More particularly this invention is directed to the isolation of the novel xanthone natural product sootepenseone from Dasymaschalon sootepense Craib, Annonaceae, its identification and derivatization, and the use of sootepenseone and its derivatives as anticancer agents. | 2 |
This application is a continuation-in-part of our application Ser. No. 642,752, filed Aug. 21, 1984, for an "Array of Electrostatically Actuated Binary Devices", application Ser. No. 642,997, abandoned, filed Aug. 21, 1984, for an "Array of Electrostatically Actuated Binary Devices and Methods of Manufacture", and application Ser. No. 642,996, filed Aug. 21, 1984, for an "Array of Electrostatically Actuated Binary Shutter Devices."
BACKGROUND OF THE INVENTION
This invention relates to electrostatically controllable electromechanical binary devices for use as an array, switching matrices, memories and the like.
The prior art contains various examples of electrostatic display elements. One type of device such as is shown in U.S. Pat. Nos. 1,984,683 and 3,553,364 includes light valves having flaps extending parallel with the approaching light, with each flap electrostatically divertable to an oblique angle across the light path for either a transmissive or reflective display. U.S. Pat. No. 3,897,997 discloses an electrode which is electrostatically wrapped about a curved fixed electrode to affect the light reflective character of the fixed electrode. Further prior art such as is described in ELECTRONICS, Dec. 7, 1970, pp. 78-83 and I.B.M. Technical Disclosure Bulletin, Vol. 13, No. 3, August 1970, uses an electron gun to electrostatically charge selected portions of a deformable material and thereby alter its light transmissive or reflective properties.
Additional instruction in the area of electrostatically controlled elements useable for display purposes can be gained from the following U.S. Pat. Nos.: 4,336,536, Kalt et al; 4,266,339, Kalt; 4,234,245, Toda et al; 4,229,075, Ueda et al; 4,208,103, Kalt et al; 4,160,583, Ueda et al; 4,160,582, Yasuo; 4,105,294, Peck; 4,094,590, Kalt; 4,065,677, Micheron et al; 3,989,357, Kalt; 3,897,997, Kalt; and, 888,241 Kuhlmann.
The present invention proceeds from material disclosed in Simpson U.S. Pat. No. 4,248,501, and Simpson et al U.S. Pat. No. 4,235,522.
Of background interest are:
W. R. Aiken: "An Electrostatic Sign-The Distec System", Society for Information Display June 1972, pp. 108-9;
J. L. Bruneel et al: "Optical Display Device Using Bistable Elements", Applied Physics Letters, vol. 30, no. 8, Apr. 15, 1977, pp. 382-3, and
R. T. Gallagher: "Microshutters Flip to Form Characters in Dot-Matrix Display", Electronics, July 14, 1983, pp. 81-2.
SUMMARY OF THE INVENTION
The present invention provides an electrostatic device for memories, switching matrices, and the like. The device takes the form of an array of electrostatic binary elements each having a plurality of electrode regions connected in columns and rows for addressing of a particular element with appropriate drive voltages to electrostatically change the state of the element. When actuated, the element forms a capacitor. The presence or absence of capacitance allows the status of the array to be "read" using a high frequency or pulse signal to determine which elements act like capacitors. The ability of the elements to change state from capacitor to non-capacitor permits use of the arrays as switching devices to deliver a signal pulse when actuated. Such switching matrices or arrays can be used to control a further array.
Simpson U.S. Pat. No. 4,248,501, Simpson et al U.S. Pat. No. 4,235,522, and Simpson et al U.S. applications Ser. No. 642,752, Ser. No. 642,997, and Ser. No. 642,996 show a variety of configurations of electrostatically actuated binary elements in which a flexible flap, curl, or shutter is driven between two positions or states by appropriate energization of electrode areas. Arrays of columns and rows of these binary elements are disclosed in which elements are addressed individually to change state for such purposes as alpha-numeric displays. The various elements disclosed in the above patents and applications are suitable for use as the binary elements of the present invention and those several disclosures are incorporated herein by reference. The present disclosure illustrates and describes a suitable generalized form of electrostatic binary element capable of execution in accordance with specific embodiments found in any of the above disclosures.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of a binary element suitable for use in the present invention.
FIG. 2 is a schematic representation of an array of binary elements.
FIG. 3 is a perspective view of a further embodiment of a binary element.
FIG. 4 is a schematic showing two switching arrays controlling a primary array.
FIG. 5 is a schematic, cross-sectional view of binary elements suitable for use as capacitive switch elements.
FIG. 6 is a schematic, cross-sectional view of a further embodiment of a binary element.
FIG. 7 is a circuit schematic of a capacitive memory using the binary elements of the present invention.
DETAILED DESCRIPTION
FIG. 1 is a schematic representation of a simplified single binary electrostatic element 10 having X, Y and latching or hold-down (HD) electrodes separated by gaps of chevron shape on a stator 11 and an electrostatically attractable flap 12 for example, a dielectric film 12a with a conductive coating 12b, shown in the form of a curl. Energization of the X electrode region will cause the flap 12 to uncurl partially. Energization of the Y electrode region will cause further uncurling and energization of the latch electrode region HD will complete uncurling and flattening of the flap 12. The drive voltages for the X and Y electrode regions can be extinguished and the flap will remain flattened so long as the latch electrode HD remains energized.
FIG. 2 is a small six by nine element array 20 of fifty four binary elements or pixels, some of which are actuated to form a visual character, in this case, the number "6". Actuation of the selected elements is achieved by providing a drive voltage to the X and Y electrode regions of the element at a particular address in the array. All X regions of each row are electrically connected together and to an X input (lead 14) for that row. All Y regions in each column are connected together and to a Y input (lead 16) for that column. Thus, to form the left side of the character "6", the column input lead Y1 and row input leads X1 through X9 are energized sequentially. Similarly, to form the right side of the character, column input lead Y6 and row input leads X1 through X5 and X9 are energized sequentially. Each selected element or pixel addressed changes state and is latched in that changed state by energization of all latch electrodes HD in the array by input lead 18. Each pixel 10 has a discrete address such as X9, Y6. Consequently, the number of external switching devices and leads required to control the small array of FIG. 2 is 9X inputs plus 6Y inputs plus one hold-down input for a total of sixteen inputs to be switched.
The number of X, Y input leads or external switching devices required to control 389,376 pixels in an array 576 by 676 is 1252 plus hold-down inputs. The number of switching devices for an array is given by: ##EQU1## where S is the minimum siwtch number, N is the number of pixels, and d is the number of mathematical array dimensions, for example d equals 2 for an X, Y array and 3 for an X, Y, Z array. In this two dimensional array, ##EQU2## external switching devices.
One way to reduce the number of external switching devices required to control an array is to increase the number of dimensions of the array. If an X, Y array is considered to be two dimensional, then an X, Y, Z array is three dimensional. FIG. 3 shows a binary element 30 similar to element 10 of FIG. 1, but having a Z electrode region and lead 17 as well. The Z electrode regions of a group of elements in an array are connected together. In FIG. 2 six Z groups (Z1 through Z6) are indicated as groups of 9 pixels bounded by dashed lines. The address of a particular element, 10 for example, becomes X9, Y6, Z2. For a three dimensional array of 389,376 pixels, the number becomes S=3∛389,376=220 external switching devices or roughly one-fifth the number required for a two dimensional array of the same number of pixels.
Another manner in which the number of external switching devices required to control an array of a large number of elements or pixels is the use of switching arrays in advance of the X and the Y leads of the pixel array. FIG. 4 is a schematic diagram showing a pixel array 90, for example 576 by 676, which has 576 X leads 92 and 676 Y leads 91 for a total of 1252 leads. A switching array 94 for the X leads and a switching array 97 for the Y leads are shown. To control the 576 leads, the switching array 94 requires 2√576=48 leads which can be distributed as 24 "A" leads 95 and 24 "B" leads 96. Similarly, the 676 Y leads can be controlled by a Y switching array 97 having 2√676=52 leads distributed as 26 "C" leads 98 and 26 "D" leads 99. By use of switching arrays, the number of external leads to be switched externally becomes 48+52=100 instead of 1252.
Address of a particular pixel, say X=250, Y=330, requires address of the proper A lead and B lead of the X switching array, and address of the proper C lead and D lead of the Y array. The address of the selected pixel (X=250; Y=330) becomes instead (A, B); (C, D) where A, B, C, and D are variables determined by the matrices of the X and Y switching arrays.
The great reduction in the number of external leads (100 instead of 1252 in this example) very considerably reduces the hardware costs of controlling a large number array. Because two switching arrays must respond before the pixel array is actuated, speed of response is reduced.
FIG. 5 is a schematic showing how electrostatically actuated elements can be used as capacitance switching devices suitable for use in the X and Y switching arrays 94 and 97. Since the switching devices are electrostatic elements similar to the pixel elements, they can be formed, for example, at the margins of the pixel display array 90 at the same time and by the same photo-etching or printing techniques as the display pixels are formed. The X and Y leads from the display directly connect with the X and Y switching arrays and are formed as a part of the photo-etch or printing process. Consequently, it is only the far fewer leads for address of the X and Y switching arrays that require external connections.
The schematic of FIG. 5 shows a pixel 110 of the X switching array and a pixel 112 of the Y switching array. The pixels of these X and Y switching arrays are not necessarily visual display elements, but are electrostatically actuated capacitance switch elements. The electrostatically attracted flaps 10X and 10Y are suggested in the curled state by dashed lines and in the actuated or flattened state by their respective conductive regions A, Xn and C, Yn. The stators, 20X and 20Y have conductive regions, respectively, COM X, B, COM X, and COM Y, D, COM Y.
The stator common electrode regions COM X are connected together as are the regions COM Y and connected to a source of alternating current. The provision of an alternating current to the appropriate row of the X switching array 94 will energize all A regions of the flaps 10X in that row, and to the appropriate column will energize all the B regions of the stators in that column. In this example, the capacitance switching pixel lying at the row, column intersection is the depicted pixel 110. It is the only pixel in the X switching array which actuates, and when actuated, electrode region Xn becomes capacitively charged and thereby produces an output signal which drives row Xn (the desired row) of the display array 90. Similarly, capacitive switching pixel 112 of the Y switching array 97 actuates to provide at electrode Yn a drive signal to the selected column Yn of the display array.
The concurrence of the drive signal Xn, Yn (the output of the X and Y switching arrays) causes actuation of the target pixel of the display array. Thus, display pixel Xn, Yn is addressed by addressing X switching pixel 110 (A, B) and Y switching pixel 112 (C, D), where A, B, C, D are address components representing the selected columns and rows of the two switching arrays and thereby represent independent address components of the target pixel of the large display array. In this manner, the number of external switching devices required to control the display array is greatly reduced as described above in connection with FIG. 4.
Cascading of switching arrays can be continued further and further to reduce the number of external leads. This technique gains in utility as the number of pixels in the display array increases. For example, a large area display array can, with triads of color pixels, become a flat, very thin television screen of unlimited size. Limitations of the number of the triads are imposed, not by the technology, but by the broadcast signal standards. Cascaded marginal switching arrays permit a cable connection of a realistic number of wires to the signal generator, TV receiver, or video recorder.
Lead reduction also is accomplished by use of three or more dimension arrays wherein each element has electrode regions for X, Y, Z . . . N drive inputs. See our U.S. Pat. No. 4,235,522, column 6 et seq. Combinations of capacitive switching arrays and three or more mathematical dimension arrays can significantly reduce the external leads and discrete components required. Using three two dimensional switching arrays to drive a single three dimensional array is the equivalent of a six dimensional array. Thus, the 100 leads required for the 389,376 pixel array as described above can control (100/6) 6 =over 21 million pixels when this combination technique is employed to achieve a six dimensional array.
FIG. 6 is a schematic, sectional view of a binary element 60 similar to those of FIGS. 1 and 3 wherein the moveable electrode 12 is in the form of a curl electrostatically attracted into an uncurled or flattened state overlying a stator 11 of dielectric material having a plurality of stator electrode regions COM, HD, X, Y, Z, and HD. The flap 12 is shown curled in dashed lines and flattened in solid lines. It has at least a conductive surface 12b such as aluminum vapor deposited on a film 12a such as polyethylene terephthalate. That conductive surface is not directly electrically connected, but is free to float electrically. The element is addressed and actuated into the flattened state by applying an electrical potential between the several stator electrode regions. Once flattened, the flat 12 will remain latched in the flattened or actuated state by virtue of the continuance of potential at the latch or hold-down electrode region HD. Once flattened, the drive potential to the X, Y, and Z electrodes is extinguished. Selected flattened flaps can be driven to the curled state by an appropriate sequence of electrode switching as is taught in our application Ser. No. 642,752.
To prevent loss of memory during a power interruption, the latching or hold-down electrodes HD can be electrets, that is a material, such as polythylene terphthalate, capable of permanent retention of electrostatic charge. The conductive electrode regions of the latching or hold-down electrodes allow the permanent charge of the electret to be overcome for actuation purposes. The status of each element will be preserved by the latching effect of the electret in the absence of electrical power.
The subject matter thus far disclosed essentially is an array or a field of binary latchable gating elements, either curled or flattened, either reflective of light or not, either a hole or not. Similar arrays can be used as a memory for computer purposes. Once programmed so that selected elements are capable of being uncurled, and the other elements are not capable of uncurling, it is a memory.
An array of elements having some capable of being actuated and some not can serve as a memory. In order to read the memory, each element in the array is provided with the drive sequence to cause overlying, if the element is capable of overlying. To ascertain whether or not the element overlies the stator, a signal pulse is directed to one electrode of that element and the other electrodes of that element are connected to a signal detector. If the stator is overlain, the signal will be detected by virtue of the capacitive coupling only available where the stator is overlain.
FIG. 7 is an array of 64 elements arranged as a three dimensional X, Y, Z array 4 by 4 by 4. For clarity, only the X, Y, and Z electrode regions are shown. The floating conductor or flap 12 is shown in dashed lines for the upper left hand element 60 having an address of X1, Y1, Z1.
The fact that only one element 60 has been actuated can be ascertained by providing a high frequency signal or pulse source 75 switchable among any of Z1 through Z4, a first signal sensor 76 switchable among any of Y1 through Y4, and a second signal 77 sensor switchable among any of X1 through X4. Only when the signal source 75 is switched to Z1 will it encounter a capacitor (element 60). The signal will capacitively couple to Y1 and to X1 and can be sensed by the sensors 76, 77 only when they are switched respectively to Y1 and X1. Thereby, the fact that element 60 has been actuated can be detected and the address resolved into X1, Y1, Z1.
Information is stored in the memory array in terms of the presence or absence of the capability of becoming a capacitor at each intersection of the columns and rows of the array. Analog values of charge are not measured, only a binary presence or absence, thereby providing a stable, reliable memory, less sensitive to electrical noise or random signals, or frequency bandwidth problems.
The array of FIG. 7 can be manufactured by photo-etching or printing techniques on a plurality of substrate films which are later laminated. The conductor leads for each electrode region are arranged in planes to prevent unwanted interconnections. Where a conductor lead for one electrode region passes over a lead for another region a further plane having a grounded conductive surface serves as an isolation shield to prevent signals from straying to the wrong lead. The seeming circuit complexity resolves into several layers of printed or photo-etched "art work" capable of low cost manufacture. Arrays of hundreds of thousands of elements can be produced in an area only a few centimeters square. Not only is the cost of the array small (only printing on film) but the number of external connections and switching devices is small, thereby reducing the over-all cost of the computer or other application hardware. | Arrays of electrostatic elements arranged in columns and rows are used for switching purposes and for memory devices. Electrostatically attracted members, for each element, when actuated, complete a capacitance device to render that element capable of retaining a charge. Whether or not the element is a capacitance device is sensed by a high frequency signal. Permanent memories can be made by substitution of a pattern of conductor areas for the attractable members. The attractable members, when attracted, form a capacitance switching device or matrix of switches. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to an expandable assembly for use in a wellbore formed in an earth formation, the assembly comprising a mechanism for increased radial expansion upon expansion. More particularly, the invention relates to a radially expandable device that mechanically engages a borehole wall so as to form an anchor.
BACKGROUND OF THE INVENTION
[0002] In the drilling of oil and gas wells, a wellbore is formed using a drill bit that is urged downwardly at a lower end of a drill string. After drilling a predetermined depth, the drill string and bit are removed, and the wellbore is typically lined with a string of steel pipe called casing. The casing provides support to the wellbore and facilitates the isolation of certain areas of the wellbore, for instance adjacent hydrocarbon bearing formations. The casing typically extends down the wellbore from the surface of the well to a designated depth. An annular area is thus defined between the outside of the casing and the earth formation. This annular area is filled with cement to permanently set the casing in the wellbore and to facilitate the isolation of production zones and fluids at different depths within the wellbore.
[0003] Expandable tubular elements are finding increasing application in the context of hydrocarbon drilling and production. A main advantage of expandable tubular elements in wellbores relates to the increased available internal diameter downhole for fluid production or for the passage of tools, compared to conventional wellbores with a more traditional nested casing scheme. Generally, an expandable tubular element is installed by lowering the unexpanded tubular element into the wellbore, whereafter an expansion device is pushed, pumped or pulled through the tubular element. The expansion ratio, being the ratio of the diameter after expansion to the diameter before expansion, is determined by the effective diameter of the expander.
[0004] When an expandable tubular is run into a wellbore, it must be anchored within the wellbore at the desired depth to prevent movement of the expandable tubular during the expansion process. Anchoring the expandable tubular within the wellbore allows expansion of the length of the expandable tubular into the wellbore by an expander tool. The anchor must provide adequate engagement between the expandable tubular and the inner diameter of the wellbore to stabilize the expandable tubular against rotational and longitudinal axial movement within the wellbore during the expansion process.
[0005] The expandable tubular is often run into the wellbore after previous strings of casing are already set within the wellbore. The expandable tubular must be run through the inner diameter of the previous strings of casing to reach the portion of the open hole wellbore slated for isolation, which is located below the previously set strings of casing. Accordingly, the outer diameter of the anchor and the expandable tubular must be smaller than all previous casing strings lining the wellbore in order to run through the liner to the depth at which the open hole wellbore exists.
[0006] Additionally, once the expandable tubular reaches the open hole portion of the wellbore below the previous casing or liner, the inner diameter of the open hole portion of the wellbore is often larger than the inner diameter of the previous casing. To hold the expandable tubular in place within the open hole portion of the wellbore, the anchor must have a large enough outer diameter to sufficiently fix the expandable tubular at a position within the open hole wellbore before continuing with the expansion process.
[0007] U.S. Pat. No. 7,104,322 discloses a method and apparatus for anchoring an expandable tubular within a wellbore. The apparatus includes a deployment system comprising an inflatable packing element. The packing is arranged inside the liner and is supported on the drill string. When inflated, the packing radially expands an anchoring portion of the expandable tubular. The outside of the anchoring portion engages the wellbore wall and forms an anchor. The remainder of the expandable tubular can subsequently be expanded using an expander tool. The holding power and shape of the anchoring portion may be manipulated by altering the characteristics of the packer such as the shape and wall thickness of the packer.
[0008] However, engagement of the tubular with the formation, as disclosed in U.S. Pat. No. 7,104,322, is limited by the amount of expansion of the tubular element, which is typically constrained by the mechanical limits of the expansion device. For instance in cases where the annulus between the unexpanded tubular and the borehole wall is relatively large, the amount of available mechanical expansion may not be sufficient to cause the expanded tubular to engage the borehole wall.
[0009] In addition, although the friction between the outside of the tubular and the wellbore wall that keeps the expandable tubular in position may withstand the reactive forces induced on the expandable tubular by a rotational expansion tool, the friction may be insufficient to withstand the reactive force when pulling an expander cone through the expandable tubular. If the friction is insufficient, the expansion tool may move the expandable element in axial direction during expansion, and the unexpanded tubular may obstruct the previous casing. The unexpanded element must then be removed, at considerable costs, or the obstruction may render the wellbore useless, at even greater expense.
[0010] Thus, it remains desirable to provide a device that will mechanically engage the borehole wall upon expansion of a tubular, even in instances where the expanded tubular does not itself engage the borehole wall.
SUMMARY OF THE INVENTION
[0011] The present invention provides a tubing-mounted device that will mechanically engage a borehole wall upon expansion of a tubular, even in instances where the expanded tubular does not itself engage the borehole wall.
[0012] A system according to the invention for anchoring an expandable tubular to a borehole wall, comprises a support member having a first end fixed relative to the outside of the tubular; and an anchor member having a first end fixed relative to the outside of the tubular and a second end extending toward the support member, said second end being movable relative to the outside of the tubular; said support member including a ramp surface that tapers in the direction of said anchor member; said first anchor end and said first support end defining an initial axial device length L 1 therebetween; wherein L 1 is selected such that expansion of the portion of the expandable tubular between the first support end and the first anchor end causes the axial device length to shorten to L 2 , wherein the difference between L 1 and L 2 is sufficient to cause the second anchor end to move radially outward and engage the borehole wall as a result of engagement with said ramp surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention is better understood by reading the following description of non-limitative embodiments with reference to the attached drawings, wherein like parts of each of the figures are identified by the same reference characters, and which are briefly described as follows:
[0014] FIG. 1 is a schematic cross-section of a first embodiment of the invention positioned in a borehole before being expanded;
[0015] FIG. 2 is a cross-sectional view of the device of FIG. 1 in an intermediate level of expansion; AND
[0016] FIG. 3 is a cross-sectional view of the device of FIG. 1 fully expanded within the borehole.
DETAILED DESCRIPTION OF THE INVENTION
[0017] FIG. 1 shows an expandable anchoring device 10 for anchoring an expandable tubular 20 to a borehole wall 11 constructed in accordance with a first embodiment of the present invention. The anchoring device 10 comprises an anchor 12 and a wedging member 16 both mounted on the outside of an expandable tubular 20 and separated by a first distance L 1 . The expandable tubular 20 may include a single tubular element, or any number of interconnected tubular elements. The tubular elements can be interconnected using threaded connections known in the art (not shown). Anchor 12 includes a fixed end 14 that is preferably affixed to tubular 20 by welding or other means that prevents relative movement between fixed end 14 and tubular 20 . The other end of anchor 12 extends toward wedging member 16 but is not affixed to the outside of tubular 20 , so that all of anchor 12 except fixed end 14 is free to move relative to tubular 20 . Anchor 12 may be constructed such that its inner diameter is the same as or, more preferably, greater than the unexpanded outside diameter of tubular 20 .
[0018] It will be understood that anchor 12 and fixed end 14 can be formed as a single, integral component, constructed from separate pieces that have been joined, or comprise separate pieces that are not mechanically joined. It is preferred that at least fixed end 14 be affixed to tubular 20 , preferably but not necessarily by welding.
[0019] Similarly, wedging member 16 is preferably affixed to tubular 20 by welding or other means that prevents relative movement therebetween. Wedging member 20 includes a ramp member 18 that extends toward anchor 12 . Ramp 18 may be constructed with any desired surface angle.
[0020] The thicknesses of wedging member 16 and anchor 12 are a matter of design, but are limited by the maximum allowable diameter of the system prior to expansion, which is smaller than the inner diameter of the previous casing string.
[0021] Anchor 12 and wedging member 16 can each have either an annular or segmented construction. In a segmented construction, anchor 12 and/or wedging member 16 may comprise longitudinal strips, rods, or plates. For example, eight strips, each extending around 45 degrees or less of the outer circumference of tubular 20 could be used. Alternatively, anchor 12 and/or wedging member 16 may include both an annular portion and a segmented portion. In the latter case, it is preferred that the annular portion lie outside of the separation distance L 1 .
[0022] It is further preferred that any fixed end and/or annular portion be made from a ductile material and have sufficient thickness and length that it can be expanded without requiring undue force. A suitable ductile material is for instance carbon steel A333. The material has for instance a modulus of elasticity with respect to tension in the order of 30 or more and with respect to torsion in the order of 11 or more.
[0023] Expandable anchoring device 10 is intended for use in conjunction with an expandable tubular 20 , which in turn is expanded by an expansion device 30 . As illustrated, expansion device 30 may comprise a cone having a frustoconical expansion surface 32 that increases the inside diameter of tubular 20 as expansion device 30 is pushed or pulled through tubular 20 , but it will be understood that expansion device 30 can comprise any suitable mechanism for applying a radial expansion force to the inside of tubular 20 .
[0024] Referring to FIGS. 2 and 3 , it can be seen that as expansion device 30 moves through tubular 20 , tubular 20 shortens. Thus, as expansion device 30 moves from one end of L 1 to the other; the distance between wedging member 16 and fixed end 14 of anchor 12 decreases. The final distance between wedging member 16 and fixed end 14 of anchor 12 is reached once expansion device 30 has moved past wedging member 16 , and is defined as L 2 . Because anchor 12 is not affixed to tubular 20 apart from fixed end 14 , the shortening of tubular 20 has virtually no effect on the length of anchor 12 .
[0025] For a given tubular and expansion ratio, the amount of shortening that will occur if the tubular is not constrained during expansion can be predicted. In a preferred embodiment, the distance L 1 is selected such that the amount of shortening, which can be expressed as the difference between L 1 and L 2 , is sufficient to cause the anchor 12 to overlap wedging member 16 by a desired longitudinal distance. The difference between L 1 and L 2 is a function of the expansion ratio, the expansion mode and, less so, of the original tubing wall thickness and can be predicted on the basis of those parameters.
[0026] As used herein, “expansion mode” distinguishes between so-called expansion in tension and expansion in compression, which in turn are used to describe stress states experienced by the tubular during expansion. During expansion in tension, the expansion device moves away from a location where the expandable tubular is fixed, which is for instance the position of an anchor. During expansion in compression the expansion device moves towards the location where the expandable tubular is fixed. The expandable tubular shortens approximately two times more during expansion in compression, than during expansion in tension. Shortening herein indicates the difference in length of (a section of) the tubular before and after expansion. During expansion of the tubular, the mode of expansion may change. In addition, the weight of the expandable tubular may introduce a second order effect. However, in general the mode of expansion is known, as is described in more detail below. Thus, it is possible and desirable to calculate and use a predetermined spacing L 1 that will result in a desired overlap and outward movement of anchor 12 .
[0027] During expansion of the expandable tubular element according to the present invention, the section of the tubular that is provided with the anchor of the invention is preferably expanded in a first step. During this first step, gripping means hold the unexpanded tubular element in a predetermined position until the anchor engages the wellbore wall. Suitable gripping means that operate in conjunction with an expansion device are for instance disclosed in US-2009/0014172-A1, which is in this respect incorporated herein by reference. In a first expansion step, the gripping means engage the wall of the tubular. Than, an actuator, including for instance a hydraulic actuator, pulls the expansion device through the tubular until the anchor is activated. In a subsequent step, once the anchor has engaged the borehole wall, the remainder of the tubular element can be expanded by pulling the expansion device toward the surface. Expansion by pulling the expander toward the surface is relatively fast compared to other ways of expansion. Expansion using the gripper system can be nominated expansion in compression, wherein pulling the expander to the surface when the anchor is activated is called expansion in tension. Thus, the mode of expansion may change when the anchor is activated and engages the borehole wall.
[0028] As an alternative to the gripping system, the string of expandable tubular elements 20 can be closed at its downhole (not shown), forming a closed fluid pressure chamber between the closed end and the expansion device 30 . I.e., the downhole end is closed at surface, before introducing the expandable tubular including the closed end and the expansion device in the wellbore. The expansion device 30 will be provided with a fluid passage connecting the top and bottom end thereof. For instance tubing of a hollow pipe string is connected to the top end of the fluid passage, to pass fluid under pressure from surface and through the expansion device into the fluid pressure chamber, wherein the resulting pressure in the fluid chamber pushes the expansion device through the expandable tubular. Expansion using a pressure chamber under the expansion device is called expansion in tension.
[0029] The expansion process of the expandable liner 20 actuates the anchoring device of the present invention. Due to the shortening of the liner as the expansion device moves from one end of L 1 to the other, the anchor 12 slides onto the ramp 18 of the wedging member 16 . In the absence of hinges, the free end of the anchor may overlap the wedging member 16 by a desired longitudinal distance. The length of the overlap is preferably minimized, in order to limit the increase in expansion force.
[0030] The free end of the anchor focuses the radial force that the anchor exerts on the formation during expansion of the liner 20 on the surface of the free end. Thus, the radial force that will be exerted per area of the formation increases. The local resistance or strength of the formation may be expressed as a resistive force per area (e.g. in units psi or Pa). The formation resistance within the wellbore may range between 500 psi up to 16000 psi, and can for instance be measured or estimated. This allows the contact area between the formation and the free end, as well as the corresponding maximum radial force on the tip to be designed such that the tip will penetrate over a predetermined minimum penetration depth into the formation during expansion of the tubular element.
[0031] The maximum anchoring force is for instance determined by one or more of the strength of the formation in conjunction with the contact area between the anchors and the formation perpendicular to the axis of the tubular, the penetration depth, the number of anchors disposed around the circumference of the tubular element, etc.
[0032] For a tubular element having an external diameter of 9⅝ inch, the anchor and/or wedging members may have a thickness in the range of 0.3 to 1 inch (1 to 2.5 cm), for instance about 0.5 inch (1.2 cm). The ramp may typically have an angle with respect to the axis of the tubular element in the order of 30 to 60 degrees, for instance about 45 degrees. The overlap is for instance 0.5 to 2 inch (1 to 5 cm). The length of the anchor may be in the range of 3 to 16 inch (7.5 to 40 cm).
[0033] The anchoring device of the invention can be scaled up or down to match any size of expandable tubular element that is commonly used when drilling for hydrocarbons. The force that is required to expand the expandable tubular element may increase locally for instance about 5% to 50% along the length of the anchoring member of the invention. The expansion force increases for instance about 10% to 20% at the position of the welds 14 , 17 . At the position of the ramp member, the expansion force may increase about 20% to 40% when the free end of the anchor 12 engages the formation.
[0034] All exemplary sizes and shapes provided above could be scaled and adapted to the external diameter of any expandable tubular element that is typically used for the exploration and production of hydrocarbons.
[0035] The present invention is not limited to the above-described embodiments thereof, wherein many modifications are conceivable within the scope of the appended claims Features of respective embodiments can for instance be combined. | The present invention provides a system for anchoring an expandable tubular to a borehole wall. The system comprises a support member having a first end fixed relative to the outside of the tubular and a second end comprising a ramping surface. An anchor member has a first end fixed relative to the outside of the tubular and a second end extending toward the support member, said second end being movable relative to the outside of the tubular. Said support member includes a ramp surface that tapers in the direction of said anchor member. Expansion of the portion of the expandable tubular between the first support end and the first anchor end causes the axial device length to shorten, wherein the difference in length is sufficient to cause the second anchor end to move radially outward and engage the borehole wall as a result of engagement with said ramping surface. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to a luminescent material having a fundamental lattice consisting of an inorganic crystalline compound, which material comprises at least 1 mol % of gadolinium, at least 0.1 mol % of an activator chosen from the group of transition metals and rare earths, and at least 0.1 mol % of a sensitizer.
A luminescent material of this type is known from Netherlands patent application 186707. In the known luminescent material, the sensitizer is chosen from the group of lead, antimony and bismuth, and the activator is chosen from the group of manganese, terbium and dysprosium. The inorganic crystalline compound and the concentrations of sensitizer and gadolinium are chosen to be such that, if no activator is present in the material but comprises only a sensitizer and gadolinium, the material has the characteristic line emission of gadolinium in the range of 310 nm to 315 nm upon excitation by UV radiation at a wavelength of approximately 254 nm. In other words, upon excitation of the material, an energy transfer from the sensitizer to gadolinium takes place. If, as in the known luminescent material, the material comprises an activator in addition to a sensitizer and gadolinium, an efficient transfer of energy also takes place from gadolinium to the activator, even at a relatively low concentration of the activator. Such a low concentration of the activator renders the luminescent material relatively inexpensive. Moreover, at such a low concentration of the activator, there is little concentration quenching so that a high luminous flux can be obtained. A drawback of the known luminescent material is, however, that the quantum efficiency is limited in that only one visible photon is generated for each exciting UV photon.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a luminescent material having a relatively high quantum efficiency.
According to the invention, the sensitizer is erbium and in that the material, if not activated but only sensitized, has the characteristic line emission of gadolinium in the range of 310 nm to 315 nm upon excitation by UV radiation at a wavelength in the wavelength range of 100 nm to 195 nm. The presence of the characteristic line emission of gadolinium, if the material does not comprise any activator but only sensitizer and gadolinium, means that energy transfer takes place from erbium to gadolinium upon excitation.
It has been found that, if a luminescent material according to the invention is excited with UV radiation of approximately 150 nm, visible light is generated by the activator as well as by the sensitizer. This is a result of the fact that at least a part of the Er 3+ ions present in the luminescent material and having absorbed an UV photon transfers the excitation energy in two steps. The 2 F 7/2 level, or the 4f 10 5d level of the Er 3+ ion is excited by the exciting radiation. By means of resonance energy transfer, a part of the energy which is absorbed by the Er 3+ ion is transferred to gadolinium, such that the 6 D j level or the 6 I j level of a Gd 3 + ion situated in the ambience of the Er 3+ ion is excited. The energy remaining at the Er 3+ ion is predominantly transferred in that the Er 3+ ion drops back from the 4 S 3/2 level to the fundamental state while emitting a green photon. The energy present at the Gd 3+ ion is transported to an activator ion by means of energy migration via a number of Gd 3+ ions. The energy is transferred to the activator ion which subsequently drops back to the fundamental state while emitting a visible photon. Since at least a part of the exciting photons is converted into two visible photons, it is possible to achieve a quantum efficiency of more than 100% with a luminescent material according to the invention. Due to the efficient energy transfer by gadolinium, the concentrations of sensitizer and activator can be chosen to be such that the sensitizer ions are spatially separated from the activator ions so that quenching due to cross-relaxation in sensitizer-activator pairs is prevented and the quantum efficiency is relatively high.
Satisfactory results have been found for luminescent materials according to the invention, in which the activator comprises one or more of the elements from the group of manganese, samarium, europium, gadolinium, terbium, dysprosium, holmium and thulium.
Preferably, the concentration of erbium is in the range of 0.1 mol % to 5 mol % and the concentration of the activator is in the range of 0.1 mol % to 1 mol %.
Satisfactory results have been obtained for luminescent materials according to the invention, which, in addition to erbium, gadolinium and the activator(s), also comprise at least one element chosen from the group of yttrium, scandium and lanthanum. These three elements are relatively inexpensive so that the luminescent material may be relatively inexpensive by making use of one or more of these elements. It has also been found that the location of the maximum of the absorption band of the luminescent material is influenced by these elements, so that addition of one or more of these elements renders it possible to obtain a good overlap of the absorption band of the luminescent material with the emission band of the excitation source. It has further been found that the presence of fluorine influences the location of the 4f 10 5d level of the Er 3+ ion in such a way that a favorable absorption behavior of the luminescent material is obtained.
Satisfactory results have been achieved with luminescent materials according to the invention in which the fundamental lattice is constituted by LiGdF 4 in which gadolinium may be partly replaced by at least one element chosen from the group of yttrium, scandium and lanthanum.
Luminescent materials according to the invention are very suitable for use in the luminescent screen of a discharge lamp, more particularly a discharge lamp provided with a gastight lamp vessel comprising xenon. A xenon discharge produces relatively much UV radiation in a wavelength range which is very suitable for exciting a luminescent material according to the invention.
These and other aspects of the invention are apparent from and will be elucidated with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE shows plots of radiation intensity vs. wavelength of emission spectra for excitation by radiation having a wavelength of 115 nm and 273 nm, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
0.140 grams of ErF 3 , 8.754 grams of GdF 3 , 0.027 grams of TbF 3 and 1.079 grams of LiF were dry-mixed in a mortar. The powder was subsequently introduced into a high-frequency heated Bridgeman set-up and consecutively heated to above the melting point and slowly cooled. The purity of the powder was checked by means of X-ray diffraction: the resultant powder appeared to be crystallographically pure. Optical measurements on the powder were performed with a spectrofluorometer adapted for measurements in the vacuum UV. Under excitation by means of radiation at wavelengths of 145 nm and 273 nm, respectively, the emission spectra shown in the FIGURE were obtained. The wavelength of the emitted light is plotted in nm on the horizontal axis. The radiation intensity is plotted in arbitrary units on the vertical axis. In the case of excitation by means of radiation having a wavelength of 145 nm, the Er 3+ ion is excited from the 4f 11 state to the 4f 10 5d 1 state. The emission spectrum of the powder has a number of lines in the blue spectrum, which are ascribed to emissions from the 5 D 3 level of the Tb 3+ ion. Furthermore, the emission spectrum in the green range shows a number of lines corresponding to emissions from the 5 D 4 level to the Tb 3+ ion. A number of lines are also visible in the emission spectrum originating from Er 3+ emission from the 4 S 3/2 level. In the UV, a Gd 3+ emission is observed at 311 nm. This emission spectrum indicates that an excited Er 3+ ion drops back from the 4f 10 5d level to the 4 S 3/2 level or to a level directly above this level upon energy transfer to a Gd 3+ ion. In the latter case, there is a rapid relaxation to the 4 S 3/2 level. The Er 3+ ion drops back from the 4 S 3/2 level to the fundamental state while emitting a green photon. The energy present at the Gd 3+ ion is transported to a Tb 3+ ion by means of energy migration via a number of Gd 3+ ions. The Tb 3+ ion absorbs the energy and subsequently drops back to the fundamental state while emitting green light.
In the case of excitation by means of radiation at a wavelength of 273 nm, the 4f 10 5d level of the Er 3+ ion is not excited. The Gd 3+ ion is excited from the 4f 7 ( 8 S 7/2 ) to the 4f 7 ( 6 I J ) state. The energy is subsequently transferred to Tb and also a little bit to Er. The emission spectrum has the same lines as upon excitation by means of radiation at a wavelength of 145 nm. The measured intensity ratios of the different Er and Tb emissions in this spectrum represent the ratios in the case where the 4f 10 5d level of the Er 3+ ion is not excited and no energy transfer takes place from Er to Tb, as in the case of excitation by means of radiation at a wavelength of 145 nm. It can be calculated from the increase of the Er( 4 S 3/2 ) emission at 145 nm excitation with respect to 273 nm excitation which percentage of the Er ions at 145 nm excitation transfers only a part of the energy to Gd so that it drops back to the 4 S 3/2 level or a level directly above it. This appears to be approximately 30% for the LiGdF 4 lattice used. | A luminescent material includes erbium, gadolinium and an activator chosen from the rare earth elements and/or the transition metals. Upon excitation with radiation having a short enough wavelength, the luminescent material acts as a quantum cutter and has a quantum efficiency of more than 100%. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a Divisional application of U.S. patent application Ser. No. 11/556/423, filed Nov. 3, 2006, now U.S. Pat. No. 7,591,118 which claims the benefit of provisional application no. 60/734,034, Filed Nov. 4, 2005.
FIELD OF THE INVENTION
The present invention relates to siding products generally, and more particularly relates to trim components for finishing corners of siding installations at an uppermost course adjacent to a soffit.
BACKGROUND
Various types of siding panels have long been used to clad the exteriors of buildings. Polymer based sidings, such as vinyl or polypropylene, have become very popular exterior finishing products primarily due to its relatively low cost and durability when compared to traditional materials such as wood or metal. Fiber cement siding products have also become very popular. In addition, polymeric and fiber cement siding products can also be provided in a wide variety of colors and patterns. Polymeric siding has an advantage in that it is more flexible and forgiving, and hence, will not deform plastically under minor impact loads. Polymeric siding is also easy to machine and cut and can be worked with common hand tools at the construction site.
While the installation of exterior siding panels is relatively straightforward, installing siding as corner structures of the building requires more labor and expertise. Common finishing techniques for siding construction at corner structures involve the placement of corner accessories around a corner structure. For siding panels simulating a clapboard installation, typical corner accessories are corner posts with receiver pockets for concealing the ends of the courses of siding panels near the wall corner. The receiver pocket also allows for a margin of safety in spacing the ends of the siding panels from an abutment to accommodate thermal expansion of the siding panels and protects the end of the wall of the siding installation from water intrusion.
Wooden shingles and shakes are another class of very popular and attractive siding products used in the construction of homes, businesses and other structures. Unfortunately, these wooden products require constant maintenance, and are extremely expensive, as well as labor intensive to install. Further, as noted above, the durability of wooden products, such as those constructed from cedar, lags far behind that of products made of synthetic materials. Because of the popularity of the aesthetics of wood shingles and shakes, a considerable number of synthetic siding products have been created that simulate the wooden appearance of, for example, cedar shingles or cedar shake shingles. These siding products are typically formed from materials such as polyvinyl chloride and polypropylene. There are also fiber cement products available that simulate shale shingles.
Once siding panels are installed onto the exterior sheathing of a structure, it often becomes necessary to place a siding corner piece over the exposed ends of the siding panels. As an alternative to a conventional corner post with a receiver pocket, efforts have been made to match the ornamental appearance of the siding panel with the corner piece appearance, so as to avoid an unaesthetic or artificial looking final structure. Examples include the simulated shake siding corners described in U.S. Pat. No. 4,015,391 to Epstein, et al. entitled “Simulated Cedar Shake Construction,” and U.S. Pat. No. 6,684,587 to Shaw, et al. entitled “Cedar Impression Siding Corner, the entireties of both of which are hereby incorporated by reference herein. Both Epstein and Shaw describe simulated cedar shake siding panels that are attached to the outside walls of a structure and a corner piece that may be used in conjunction with shake impression siding panels to provide the look of a corner having finished shakes with mitered joints.
As the siding installation process proceeds up the wall to the soffit, it will often be the case that a course of siding will need to be trimmed horizontally to the appropriate dimension to fit on the wall. A trim accessory piece is desirable to produce an aesthetically pleasing transition from the siding installed vertically up the wall to the soffit that meets the siding under the eave of the roof. This transition can be provided by installation of a cornice receiver strip above the upper edge of the uppermost siding panel adjacent the soffit area. A cornice molding strip is then installed in the receiver for covering the upper edge of the uppermost siding panel and producing an aesthetically pleasing transition to the soffit.
In cases where a corner post having a receiver pocket is used in the siding installation, the ends of the trim pieces will be concealed within the receiver pocket. However, for more decorative corners simulating shake impressions, such as, for example, U.S. Pat. No. 4,015,391 to Epstein and U.S. Pat. No. 6,684,587 to Shaw, there is no pocket to conceal the end of trim. In order to attain an aesthetically pleasing corner of the trim accessory, another approach is necessary.
One approach would be to trim the ends of the cornice molding to produce a mitered corner joint. However, this process is laborious and time consuming and requires special carpentry skills. It also would yield a tightly fitted corner joint that could be damaged by distortion caused by thermal expansion and contraction with dimensional changes of a polymeric cornice molding trim accessory.
Another approach is for the contractor in the field to finish the cornice molding at the outside corner by fabricating a corner cap out of coated aluminum coil and mounting it over the ends of the cornice molding strips at the corner structure adjacent the soffit. This approach, while potentially providing space to allow for a rougher end cutting of the cornice trim and allowing for dimensional changes of the strip, suffers from the need for time, labor, and special skills in metal working to produce an aesthetically pleasing corner cap. Also, an aluminum cap could be susceptible to denting and permanent deformation or other damage or dislodgement by impacts or winds. These difficulties have led some users to avoid the use of siding products that do not employ corner posts having siding receiver pockets and avoiding the use of exposed polymer based cornice molding strips that require a mitered joint finish at the corner.
Therefore, there remains a need for a corner piece that provides the appearance of a more natural termination of the cornice molding trim strip above the uppermost course of a siding installation employing an aesthetic corner piece, and a corner piece that is easy to use and install that accommodates thermal expansion and contraction of the trim strip and is less susceptible to damage or displacement by impacts or winds.
SUMMARY OF THE INVENTION
In embodiments of the present invention, a preformed cornice molding corner cap is provided for use in conjunction with a cornice molding strip as a part of an exterior siding installation at a corner structure provided by two mating walls. The corner cap is of unitary construction and has a top and bottom, a decorative exterior and an interior, an upper surface and a lower surface, and upper and lower retainer flanges. The cap includes first and second decorative exterior surfaces meeting at a corner, the exterior surfaces being aesthetically of complementary shape to a cornice molding trim accessory strip. The corner cap also includes first and second interior surfaces, the profiles of which are physically of complementary shape to the outer surface of the cornice molding accessory so as to receive an end of a cornice molding strip within the interior of the cornice molding corner cap.
The cornice molding corner cap cooperates with the cornice molding strip to cover the gap between cornice molding strips attached to adjacent walls mating at a corner structure, to give the appearance of a finished mitered corner of the decorative molding, and to cover the upper edge of an uppermost course of siding panel and siding corner piece, and to align ends of the cornice molding strips horizontally with each other and/or against an underside of a soffit under an eve of a roof.
In certain embodiments, the present invention also provides a method of finishing a corner of an uppermost course of a siding installation. In the method, an uppermost courses of siding panels on each of two adjacent walls that meet at a corner structure are installed, a siding corner piece is installed at the corner structure, first and second cornice molding strips are installed on each of the walls above the top edge of the uppermost courses of siding panels under an eave or soffit structure, with the ends of the cornice molding strips having a gap between them adjacent the corner and a gap between an end of each molding strip and the edge of the corner structure. A preformed cornice molding corner cap is provided and the corner cap is installed over the ends of each of the cornice molding strips, thereby concealing the gap between the ends of the cornice molding strips and between the ends of the strips and the edge of the corner structure, thus effectively covering the corner. In some instances when installing the cornice molding corner cap, the upper retainer flange of the cornice molding corner cap is hooked over the top edge of ends of the first and second cornice molding strips and the lower retainer flange is pivoted downward to become snap-fit and hooked under the bottom edge of the cornice molding strips to mount the cap in place in a snap-fitting relation. In other instances, the cornice molding corner cap is installed by sliding the cornice molding corner cap over the end of the first cornice molding strip until the cap overlaps and aligns with the surface of the second cornice molding strip adjacent to the corner, and snap inserting the second cornice molding strip into the interior of the corner cap by biasing the retaining flanges against the second cornice molding strip to widen a receiver channel for receiving the second cornice molding strip.
In certain embodiments, the present invention also provides a system and an assembly for the finishing of a corner of a siding installation having an uppermost course of siding on each of two adjacent walls that meet at a corner structure, a siding corner piece installed at the corner structure, and first and second cornice molding strips installed on each of the walls above the top edges of the uppermost courses of siding panels under an eave or soffit structure, with the ends of the cornice molding strips having a gap between them adjacent the corner. The system and the assembly further include a preformed cornice molding corner cap installed over the ends of each of the two cornice molding strips at the corner structure, thereby concealing the gaps between the ends of the cornice molding strips and covering the corner. The cornice molding corner cap accommodates thermal expansion of the cornice molding strip and is resistant to displacement. The corner cap also acts to create a barrier at the joint of the cornice molding trim to minimize intrusion of water or insects into the building structure at the top of the wall corner.
The preformed cornice molding corner cap, method, system and assembly enable easy finishing of corners of siding installations employing shake shingle impression siding, as well as, other siding installations employing finished corner pieces without the use of a corner post having a receiver pocket for siding panel ends. The preformed cornice molding corner cap is useful for trim applications on buildings clad with polymeric siding such as vinyl or polypropylene, fiber cement siding, or other types of siding, cladding or sheathing where a finished mitered corner trim appearance is desired.
Embodiments according to the invention include, but are not limited to the several embodiments of the invention that will now be described.
An article of manufacture comprises a unitary cornice molding corner cap having a top and a bottom, and an interior and an exterior, a top receiver flange and a bottom receiver flange, the cap being capable of receiving a first end of each of a first and second cornice molding strips within the interior of the cornice molding cap.
An article as described above wherein the cornice molding cap further comprises an injection molded cap formed from a material comprising a polymer selected from the group consisting of polyvinylchloride polymers and copolymers, polypropylene polymers and copolymers, acrylonitrile butadiene styrene copolymers, acrylonitrile styrene acrylate copolymers and mixtures thereof.
A method of finishing a corner of an uppermost course of a siding installation, the method comprising the steps of installing the uppermost course of siding on each of two adjacent walls, the walls meeting at a corner structure; installing a siding corner piece at the corner structure; installing a first and a second cornice molding strip on each of the walls over a top edge of the uppermost course of siding panels, the top edge being under an eave or soffit structure, each of the first and second cornice molding strips having a first end proximate the corner structure, there being a gap between the first ends and the corner structure and a gap between the first ends of the first and second cornice molding strips; providing a cornice molding corner cap having a top and a bottom, and an interior and an exterior, and capable of accommodating the first end of each of the cornice molding strips within the interior of the cornice molding cap; and, installing the corner cap over the ends of each of the cornice molding strips, thereby concealing the gaps between the ends of the cornice molding strips.
In another embodiment of a method of finishing a corner of an uppermost course of a siding installation, the method comprises the steps of installing the uppermost course of siding on each of two adjacent walls, the walls meeting at a corner structure; installing a siding corner piece at the corner structure; installing a first and a second cornice molding strip on each of the walls over a top edge of the uppermost course of siding panels, the top edge being under an eave or soffit structure, each of the first and second cornice molding strips having a first end proximate the corner structure, there being a gap between the first ends and the corner structure and a gap between the first ends of the first and second cornice molding strips; providing a cornice molding corner cap having a top and a bottom, and an interior and an exterior, and capable of accommodating the first end of each of the cornice molding strips within the interior of the cornice molding cap; and, installing the corner cap over the ends of each of the cornice molding strips, thereby concealing the gaps between the ends of the cornice molding strips, the method further comprising attaching a cornice receiver to each of the adjacent walls; snapping the cornice molding into the cornice receiver; hooking the top of the cornice molding corner cap over the ends of the first and second cornice molding strips and snapping the bottom of the cornice molding cap into place.
In yet another embodiment of a method of finishing a corner of an uppermost course of a siding installation, the method comprises the steps of installing the uppermost course of siding on each of two adjacent walls, the walls meeting at a corner structure; installing a siding corner piece at the corner structure; installing a first and a second cornice molding strip on each of the walls over a top edge of the uppermost course of siding panels, the top edge being under an eave or soffit structure, each of the first and second cornice molding strips having a first end proximate the corner structure, there being a gap between the first ends and the corner structure and a gap between the first ends of the first and second cornice molding strips; providing a cornice molding corner cap having a top and a bottom, and an interior and an exterior, and capable of accommodating the first end of each of the cornice molding strips within the interior of the cornice molding cap; and, installing the corner cap over the ends of each of the cornice molding strips, thereby concealing the gaps between the ends of the cornice molding strips, the method further comprising sliding the cornice molding corner cap over the first end of the first cornice molding strip; aligning the corner cap with the first end of the second cornice molding strip; and, inserting the first end of the second cornice molding strip into the interior of the corner cap.
In yet another embodiment of a method of finishing a corner of an uppermost course of a siding installation, the method comprises the steps of installing the uppermost course of siding on each of two adjacent walls, the walls meeting at a corner structure; installing a siding corner piece at the corner structure; installing a first and a second cornice molding strip on each of the walls over a top edge of the uppermost course of siding panels, the top edge being under an eave or soffit structure, each of the first and second cornice molding strips having a first end proximate the corner structure, there being a gap between the first ends and the corner structure and a gap between the first ends of the first and second cornice molding strips; providing a cornice molding corner cap having a top and a bottom, and an interior and an exterior, and capable of accommodating the first end of each of the cornice molding strips within the interior of the cornice molding cap; and, installing the corner cap over the ends of each of the cornice molding strips, thereby concealing the gaps between the ends of the cornice molding strips, wherein the providing step comprises molding the corner cap from a material comprising a polymer selected from the group consisting of polyvinylchloride polymers and copolymers, polypropylene polymers and copolymers, polyethylene polymers and copolymers, acrylonitrile butadiene styrene copolymers, acrylonitrile styrene acrylate copolymers, acrylate ethylene styrene copolymers, and mixtures thereof.
In yet another embodiment of a method of finishing a corner of an uppermost course of a siding installation, the method comprises the steps of installing the uppermost course of siding on each of two adjacent walls, the walls meeting at a corner structure; installing a siding corner piece at the corner structure; installing a first and a second cornice molding strip on each of the walls over a top edge of the uppermost course of siding panels, the top edge being under an eave or soffit structure, each of the first and second cornice molding strips having a first end proximate the corner structure, there being a gap between the first ends and the corner structure and a gap between the first ends of the first and second cornice molding strips; providing a cornice molding corner cap having a top and a bottom, and an interior and an exterior, and capable of accommodating the first end of each of the cornice molding strips within the interior of the cornice molding cap; and, installing the corner cap over the ends of each of the cornice molding strips, thereby concealing the gaps between the ends of the cornice molding strips, wherein the providing step comprises molding of the corner cap using a process comprising injection molding.
In an embodiment of a siding installation having a corner structure, the siding installation comprises a first wall and a second wall, the walls meeting in a corner structure; a covering of siding material applied to each wall; a first cornice molding strip and a second cornice molding strip applied to each wall above an uppermost course of siding material, the cornice molding strips each having a first end proximate to the corner structure, the cornice molding strips having a gap between the first ends of each strip; a cornice molding cap installed over the first ends of each cornice molding strip, the cap covering the gap, the cap exhibiting a retention force of greater than about 5 lbs.
In an embodiment of a system for finishing a corner, the system comprises a cornice molding corner cap in combination with various other elements as disclosed and described herein.
The above and other features of the present invention will be better understood from the following detailed description of the preferred embodiments of the invention that is provided in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of the exterior of an exemplary cornice molding corner cap according to the present invention.
FIG. 2 is an inside perspective view of the interior of an exemplary cornice molding corner cap according to the present invention.
FIG. 3 is a perspective view of an exemplary cornice molding corner cap according to the present invention showing interior and exterior portions of the cap.
FIGS. 4 a and 4 b are each side elevation views of an exterior surface of the exemplary cornice molding corner cap of FIG. 1 .
FIGS. 5 a and 5 b are each side elevation views of an interior surface of the exemplary cornice molding corner cap of FIG. 2 .
FIG. 6 is a perspective view of an assembly including an exemplary cornice molding corner cap and a cornice molding trim accessory strip.
FIG. 7 is a perspective view of the assembly shown in FIG. 6 .
FIG. 8 is a perspective view of a cornice molding receiver strip.
FIG. 9 is a perspective view of a cornice molding trim accessory strip.
FIG. 10 is an end elevation view of a cornice molding trim accessory strip as in FIG. 9 engaged in a cornice molding receiver strip as in FIG. 8 .
FIG. 11 is an end elevation view of a cornice molding trim accessory strip engaged in an F-channel cornice receiver strip.
FIG. 12 is a perspective view of a wall corner having a siding corner piece and F-channel cornice receiver strips attached thereon.
FIG. 13 is a perspective view of cornice molding trim accessory strips being wall mounted and attached to the F-channel cornice receiver strips of FIG. 13 .
FIG. 14 is a perspective view of an exemplary cornice molding corner cap according to the present invention attached to the F-channel cornice molding trim accessory strips of FIG. 13 .
FIG. 15 a is a perspective view of a wall corner having an exemplary uppermost course of siding panel mounted thereon, and an exemplary cornice receiver strip mounted thereon.
FIG. 15 b is a perspective view of a wall corner having F-channel cornice receiver strips mounted thereon, and siding panels and a siding corner piece mounted thereon.
FIG. 15 c is a perspective view of the wall corner of FIG. 15 b , wherein cornice molding trim accessory strips have been mounted to the walls meeting at the outside corner by F-channel cornice molding receiver strips.
FIG. 15 d is a perspective view of an exemplary cornice molding corner cap according to the present invention attached to the cornice molding trim accessory strips of FIG. 15 c.
FIG. 16 a is a perspective view of a lateral force resistance test performed on an assembly including receiver strips, cornice molding trim accessory strips, and an exemplary cornice molding corner cap according to the present invention mounted on a wall corner.
FIG. 16 b is a perspective view of the test of FIG. 16 performed at a later stage of the lateral force resistance test.
FIG. 17 a is a perspective view of a tensile force resistance test performed on an assembly including receiver strips, cornice molding trim accessory strips, and an exemplary cornice molding corner cap according to the present invention mounted on a wall corner.
FIG. 17 b is a perspective view of the test of FIG. 17 being performed at a later stage of the test.
DETAILED DESCRIPTION
In embodiments, the present invention provides a preformed cornice molding corner cap for use in conjunction with a cornice molding trim strip as a part of an exterior siding installation at a corner structure provided by two mating walls. FIGS. 1 through 5 illustrate an exemplary embodiment of a cornice molding corner cap 10 for covering a cornice molding trim accessory strip at an “outside corner” of a structure. By “outside corner”, it is meant that the corner piece has an exterior surface that extends along an angle comprising an obtuse angle to cover the cornice molding on an outwardly protruding or “outside” corner of a structure, or as opposed to the angle comprising an acute angle in which the surface is inwardly formed or on an “inside” corner of a structure. While FIGS. 1 through 5 portray a cap for an outside corner, cornice molding corner caps of appropriate geometry to cover cornice molding trim strips at an inwardly formed corner or inside corner with many of the features and advantages of the cap for an outside corner are also contemplated.
Referring more specifically now to FIGS. 1 through 5 , the cornice molding corner cap 10 (alternatively, 430 in FIG. 14 or 1230 in FIG. 15 d ) is of unitary (i.e., one-piece) construction and with a body portion that has a top 11 and bottom 12 , a decorative exterior 13 and an interior 14 , an upper surface 15 and a lower surface 16 , first 20 and second 21 lateral edges, and upper and lower retainer flanges 23 and 26 . Upper and lower retainer flanges 23 and 26 each include therebetween a horizontal receiver channel 24 and 27 extending to an interior corner 22 each retainer flange having a lip 25 and 28 . The cap includes first 17 and second 18 decorative exterior surfaces meeting at a corner 22 wherein the corner 22 extends to the interior of the body portion, the exterior surfaces being aesthetically of complementary shape and exterior finish to complement that of a cornice molding trim accessory strip 41 (alternatively 90 , 103 , 111 , 320 , 321 , 420 , 421 , 1120 , 1121 , 1220 or 1221 referred to elsewhere herein). The corner cap 10 also includes first 30 and second 31 interior surfaces, the profiles of which 32 and 33 are physically of complementary shape to the outer surfaces of the cornice molding trim accessory strips 41 so as to receive slidably horizontal cornice molding trim accessory strips 41 within the receiver channels 24 and 27 that extend laterally horizontal and through opposite sides of the cap 10 . In one presently preferred embodiment, the corner cap 10 has a dimension of about 2.6 inch between the upper and lower surfaces 15 , 16 and a dimension of about 2 inches between each given lateral edge 20 , 21 and the corner 22 measured while traveling horizontally across the upper surface 15 from the edge to the corner.
FIG. 6 discloses an assembly 40 including a cornice molding corner cap 10 engaged with a cornice molding trim accessory strip 41 . FIG. 7 shows the assembly 40 from a different angle. The molding accessory strip 41 is assembled without fasteners while engaged horizontally slidably between and within the upper 24 and lower 27 receiver channels that open toward each other and are within the upper 23 and lower 26 retaining flanges of the cap 10 , the end 42 of the cornice molding accessory strip 41 and detailed portions of the cap within the interior 14 of the cap being shown in phantom. The molding accessory strip 41 is horizontally free without fasteners therethrough to move horizontally within and relative to the cap 10 due to environmental conditions, including but not limited to, thermal expansion and contraction, wind force and earth movement. The absence of fasteners avoids unsightly exposure thereof, as well as, avoids damage by hammer blows or screwdriver gouges, and permits ease of assembly by resiliently deflecting the flanges 23 and/or 26 of the cap 10 to widen the space between the upper and lower retaining flanges 23 , 26 , and snap fit and latch the cap 10 over the strips 41 , by resilient return of the cap 10 to its original configuration prior to resilient deflection thereof. In this embodiment, the retainer flanges 23 , 26 have a dimension of about 0.25 inch from upper or lower surface 15 , 16 to flange lip 25 , 28 . In some embodiments, preferably the upper and lower retainer flanges 23 , 26 are between about 0.1 and 0.4 inch in dimension, more preferably about 0.1 to 0.3 inches. This dimension provides a balance in adequate mechanically latching onto the cornice molding accessory strip 41 without interfering with the functionality of other parts of the molding accessory strip 41 , such as, for example, a mounting flange 91 (alternatively 104 or 112 elsewhere herein) in use with a cornice molding trim accessory strip 41 .
FIG. 8 shows a section of cornice receiver strip 80 (alternatively 101 , 910 or 1010 elsewhere herein) having a receiver channel 81 (alternatively 114 , 102 , 214 , 314 , 911 or 1011 elsewhere herein) and a fastening flange 82 . The receiver channel 81 has a retainer flange 84 for engaging a mounting flange 91 , 104 or 112 from an accessory strip, such as, a cornice molding trim accessory strip 103 , alternatively 41 , 90 , 111 , 320 , 321 , 420 , 421 , 1120 , 1121 , 1220 or 1221 , that is to be mounted to a surface by using the retainer flange 84 of the receiver strip 80 . In FIG. 10 , the mounting flange 104 , alternatively 9 or 112 , is inserted into the receiver channel 81 by resiliently biasing the retainer flange 84 to move and widen the narrow entrance to the receiver channel 81 , followed by return movement of the retainer flange 84 due to stored spring energy to partially envelop the mounting flange 104 and interlock in place the accessory strip 103 . A ledge 85 is formed by doubling back the strip 80 at the entrance to the receiver channel 81 . The fastening flange 82 is equipped with fastening holes 83 to enable attachment to a wall by mechanical fasteners such as nails, screws, staples, rivets, snaps, hook and loop fasteners, or the like. Adhesives could also be used to attach a receiver strip 80 to a wall. The fastening holes 83 are preferably elongated horizontally as shown in FIG. 8 to accommodate thermal expansion and contraction of the strip and ease fastener placement during installation.
FIG. 9 shows a cornice molding trim accessory strip 90 having an exterior surface 92 and an exterior surface profile 93 . The exterior surface 92 and the exterior profile 93 provide aesthetic benefit to a siding installation, for example, in the transition region between the wall and a soffit or eave 108 in FIG. 15 d . The cornice molding trim accessory strip 90 also has a mounting flange 91 (alternatively 104 or 112 referred to elsewhere herein) for attachment to a wall or other surface using a molding receiver strip 80 having a receiver channel 81 and a retainer flange 84 . The cornice molding trim accessory strip 90 has a projecting upper lip 94 defining an upper part of the profile 93 and an depending bottom 325 upturned at the end and providing a covering skirt or covering flange to cover and conceal an uppermost course of siding or siding panel 204 , 205 , 904 , 1005 , 1105 , 1106 , 1205 or 1206 and an uppermost part of a siding corner piece 208 , 408 , 1007 , 1107 or 1207 . The upper lip 94 may abut a soffit 1208 , FIG. 15 d , below and against which the molding strip is installed, and/or may also provide a geometric feature to aid in the attachment of other items or accessories such as, for example, the cornice molding corner cap 10 of the present invention, to the cornice molding strip.
FIG. 10 depicts an assembly 100 in which a cornice molding trim accessory strip 103 is attached to a cornice receiver strip 101 . The receiver channel 102 of 101 receives the mounting flange 104 of 103 in a friction fit to hold the cornice molding trim accessory strip 103 in place. The retainer flange 84 biases as a resiliently deflected cantilever beam against the mounting flange 104 . Subsequently, the assembly 100 is assembled with a cornice molding corner cap 10 , by snap fitting the cap 10 over the two cornice molding trim accessory strips 103 adjacent the corner. The upper retaining flange 23 is hooked onto and conforms tightly to the raised upper lip 94 of each accessory strip 103 and is wedged between the upper lip 94 and the doubled back flange 85 above the entrance to the receiver channel 102 . The corner cap 10 is present to cover a portion of the raised upper lip 94 without entering the receiver channel 102 to interfere with or distort the cornice receiver strip 101 or the F-channel cornice receiver strip 113 , FIG. 11 , whichever is used. Where the cap 10 is not present, the lip 94 is biased against the flange 85 by the inherent bias and friction fit of the mounting flange 104 and the retainer flange 84 . Thus the thickness of the upper retaining flange 23 on the corner cap 10 has a thickness that is readily covered by the lip 94 without opening the lip 94 to form a gap behind the lip 94 . The flange 26 at the bottom 12 of the cap 10 snap fits over the bottom 325 or 327 of the corresponding cornice molding trim accessory strip 320 or 321 and wedges between the bottom 325 or 327 and an uppermost course of siding panel described hereafter with reference to 204 , 205 , 904 , 1005 , 1006 , 1205 or 1206 and between the bottom 325 or 327 and an uppermost course of siding corner piece described hereafter with reference to 208 , 408 , 1007 , 1107 or 1207 . In the absence of the corner cap 10 the bottom 325 or 327 is turned inward with a rounded chamfer to emulate a chamfered trim board when viewed. The bottom 325 or 327 is biased by inherent cantilever beam resiliency in the strip 320 or 321 to engage the uppermost courses of siding panel and siding corner piece, and the bottom 325 or 327 is flexible to conform against surface dimension irregularities without causing a visibly noticeable gap. Accordingly, the thickness of the lower retaining flange 26 is sufficiently thin for being readily covered and conformed against by the bottom 325 or 327 without opening the bottom 325 or 327 to form a visibly noticeable gap behind the bottom 325 or 327 .
FIG. 11 depicts an assembly 110 in which a cornice molding trim accessory strip 111 is attached to an F-channel cornice receiver strip 113 (alternatively 211 , 212 , 311 or 312 elsewhere herein). The F-channel strip is equipped with a soffit receiver pocket 115 that serves to receive a soffit panel of a soffit 1208 , FIG. 15 d , above the cornice molding trimmed siding installation. The receiver channel 114 of the F-channel cornice receiver strip 113 receives the mounting flange 112 in a friction fit to interlock and hold the cornice molding trim accessory strip 111 in place. Except for having the F-channel receiver strip 113 the F-channel cornice receiver strip 113 has the same features as the cornice receiver strip 80 (alternatively 101 , 910 and 110 elsewhere herein). The cap 10 is subsequently assembled to the assembly 110 similarly as described with reference to FIG. 10 wherein the cap 10 is assembled to the assembly 100 . The features of the cap 10 in the assembly 100 similarly apply to the assembly 110 .
FIGS. 12 to 14 show there are sequential steps in the installation and placement of a cornice molding corner cap of the present invention on a wall. In FIG. 12 , an assembly 200 is presented including siding panels, siding corner pieces and cornice molding retainer strips. A first wall 201 and a second wall 202 meet at a corner structure 203 having a corner structure edge 210 . An uppermost course of siding panels 204 on the first wall 201 and an uppermost course of siding panels 205 on the second wall 202 are shown in phantom under a siding corner piece 208 . The first uppermost course 204 has an upper edge 206 and the second uppermost course 205 has an upper edge 207 . The ends of the phantom siding panels 204 , 205 are covered by siding corner piece 208 , the corner piece having an upper edge 209 . First and second cornice receiver strips 211 and 212 , each having a soffit receiver pocket 213 and a cornice receiver channel 214 , are attached to the first and second walls 201 , 202 by fasteners 215 . The cornice receiver strip is preferably spaced above the upper edge of the siding panels 206 , 207 by a gap of about 0.25 inch. The ends of the cornice molding receiver strips 221 , 222 are spaced slightly back from the edge 210 of the corner structure 203 . This spacing allows for dimensional changes that may occur in the strips in use. A preferred spacing of the ends of the receiver strips 221 , 222 from the edge 210 is about 0.25 inch. Spacing of the ends from the edge could be greater, however, if desired, as long as there is a sufficient length of receiver strip mounted on the wall to retain a subsequently applied molding strip in place.
In FIG. 13 , an assembly 300 is presented similarly to assembly 200 of FIG. 12 , but with the addition of having had cornice molding strips 320 , 321 installed into cornice receiver channels 314 to mount the cornice molding accessory strips to the walls 301 , 302 . The first wall 301 and the second wall 302 meet at a corner structure 303 having a corner structure edge 310 . An uppermost course of siding panels 304 on the first wall 301 and an uppermost course of siding panels 305 on the second wall 302 are shown in phantom. The first uppermost course 304 has an upper edge and the second uppermost course 305 has an upper edge, the upper edges being not shown as they are covered by the cornice molding strip. The ends of the phantom siding panels 304 , 305 are covered by the uppermost course of siding corner piece 308 , the corner piece having an upper edge that is also concealed by the cornice molding strip. First and second cornice receivers 311 and 312 , each having a cornice receiver channel 314 , are attached to the first and second walls 301 , 302 by fasteners which are not shown, as they, too, are concealed by the cornice molding accessory trim strip. The cornice molding strips 320 , 321 are installed by being snapped into the receiver channels 314 of the receiver strips 311 , 312 . The cornice molding accessory strips each have a top 324 , 326 , a bottom 325 , 327 and ends 330 , 331 , respectively. The ends of the cornice molding receiver strips 314 and the ends 330 , 331 of the cornice molding accessory strips 320 , 321 are spaced slightly back from the edge 310 of the corner structure 303 . The ends of the two molding strips 330 , 331 have a gap 322 between them and the molding strips have a gap 323 between each end 330 , 331 and the edge 310 of the corner structure 303 . This spacing allows for dimensional changes that may occur in the strips in use. A preferred spacing of the ends of the receiver strips 311 , 312 and the molding strips 320 , 321 from the edge 310 is about 0.25 inch. Spacing of the ends of the molding strips 320 , 321 from the edge 310 could be greater, however, if desired, as long as there is a sufficient length of cornice molding strip mounted on the wall at the corner to enter the receiver channels to be engaged by the retainer flanges 23 , 26 of a subsequently applied cornice molding corner cap 10 and to hold the cap 10 in place in place.
FIG. 14 shows assembly 400 , including first and second walls 401 , 402 that mate in a corner structure 403 having an edge 410 . First and second cornice molding trim accessory strips 420 , 421 are mounted on the walls covering an upper edge of a siding corner piece 408 . A cornice molding corner cap 430 of the present invention is installed at the corner covering the ends of the cornice molding strips 420 , 421 and the upper edge of the siding corner piece 408 . The cornice cap 430 is installed by hooking the top of the cornice cap 430 over the end of the cornice molding strips 420 , 421 and pivoting the lower flanges 26 to engage and bias against the strips 420 , 421 and snapping the bottom 12 into place. Alternatively, the cap 430 is installed by sliding a first receiver channel of the cap 430 over the end of the first of the cornice molding strips 420 or 421 until the second receiver channel of the cap 430 is aligned with the second of cornice molding strips 420 or 421 . If the ends of the cornice molding strips 420 or 421 , or both can be pulled manually out from the wall slightly without causing permanent bending thereof, the end of the second of the cornice molding strips 420 or 421 can be aligned with the second receiver channel of the cap 430 and then inserted into the second receiver channel of the cap 430 . Alternatively, if the cornice molding strips 420 or 421 can not be pulled manually out from the wall without causing permanent bending thereof, the second cornice molding strip 420 or 430 is inserted by manually urging the interior of the cap 430 against the surface of the second of the cornice molding strips 420 or 421 , followed by inserting the second cornice molding strip 420 or 421 into the cap 430 by biasing apart the upper and lower flanges 23 , 26 against the second cornice molding strip 420 or 421 and snap fitting the cap 430 onto and over the second cornice molding strip 420 or 421 . Further details of the cap 430 will be described with reference to the cap 1230 in FIG. 15 d.
Another assembly 900 is shown in FIG. 15 a , in which a first wall 901 and a second 902 wall meet at a corner structure edge 903 . An uppermost course of siding panel 904 , the panel having an end edge 905 and a top edge 906 , is attached to the second wall 902 by a fastener 908 through fastener hole 907 . A cornice receiver 910 having a receiver channel 911 is attached to the wall 902 above the siding panel 904 . In finishing the upper edge 906 of uppermost course of siding 904 , the upper edge is trimmed for appropriate fit on the wall below the soffit area. A nail slot punch can be used to punch nail slots about 0.25 inch from the trimmed edge 905 of the siding panel so as to enable fastening of the panel to the wall in the case where the height of the top of the wall does not coincide with an integral number of courses of siding panel. Such nail slots are necessary for fastening when a preformed nail hem has been trimmed from the upper edge 906 of the panel 904 . The end edge 905 of the panel will later be concealed under a siding corner piece in completing the installation. The cornice receiver 910 is preferably spaced about 0.25 inch above the top edge 906 of the uppermost course of siding panels 904 .
In FIG. 15 b , the next step of finishing of a siding corner installation is shown as assembly 1000 . First and second walls 1001 , 1002 meet at a corner structure edge 1003 . Uppermost course of siding 1005 is attached to the first wall 1001 and uppermost course of siding 1006 is attached to the second wall 1002 . An uppermost siding corner piece 1007 is mounted on the corner, concealing the ends of the siding panels 1005 , 1006 . Cornice receiver strips 1010 having receiver channels 1011 are mounted on the wall at a position above the top edge of the uppermost courses of siding such that the ends 1012 of the cornice receiver strips are recessed or spaced slightly away from the corner structure edge 1003 . The receiver strips are attached by fasteners 1014 through fastener holes 1013 . Spacing of the receiver strips is preferably about 0.25 inch above the top edge of the siding panels. The spacing of the receiver strip ends 1012 away from the corner edge 1003 is preferably also about 0.25.
In FIG. 15 c , the resulting assembly 1100 of a further step in the finishing of a corner is presented. Adjacent a corner structure edge 1103 are provided an uppermost siding course 1105 on a first wall and an uppermost course of siding 1106 on a second wall, each course having a terminal end proximate to the corner structure edge, and having the terminal ends covered and concealed by an uppermost siding corner piece 1107 . The cornice receiver strips of FIG. 15 b have been covered by cornice molding strips 1120 , 1121 , each molding strip having an end 1122 , 1123 near the corner structure edge 1103 . The cornice molding strips are retained without fasteners and horizontally slidable in receiver channels of receiver strips analogously to the representation of FIG. 13 into which the mounting flange of the molding strips were snapped. There is a gap 1125 between each cornice molding strip end and the corner structure edge. The gap allows for horizontal thermal expansion and contraction of the cornice molding strips during use without the possibility of contact or interaction of the ends with each other and without restraint by fasteners therethrough, either of which could result in distortion or buckling of the molding strips. The gap also allows for ease and speed of installation, as the length of the molding strip near the edge of the wall does not need to be as precise as in the case of the forming of a fine structure such as a mitered corner of the molding strip itself. The gap is preferably on the order of about 0.25 inch, but could vary to the extent that once a cornice molding corner cap (not shown in 15 c ) is installed, a sufficient portion of each of the molding strip ends 1122 , 1123 is contained within the cap to hold the cap in place.
In the assembly 1200 of FIG. 15 d , the cornice molding corner cap 1230 is in place at a wall corner covering the gap between the ends of two cornice molding strips 1220 , 1221 mounted on walls clad with uppermost courses of siding 1205 , 1206 and a siding corner piece 1207 . The molding strips 1220 , 1221 and corner cap 1230 cover the uppermost edges of the siding panels 1205 , 1206 and siding corner piece 1207 to create a finished wall corner. The cornice molding corner cap 1230 has an aesthetic aspect complementary to the cornice molding strips 1220 , 1221 . Further, the cap 1230 is installed as described with reference to the cap 430 in FIG. 14 , such that the body portion of the cap 1230 is in front of and concealing respective ends 1122 , 1123 of the cornice molding trim accessory strips 1220 , 1221 , while the respective ends 1122 , 1123 are spaced apart from each other at the interior corner 22 of the body portion of the cap 1230 to allow for said expansion and contraction without engaging each other and without abutting the interior corner 22 . Further, in the cap 1230 the upper retainer flanges 23 are horizontally aligned with each other, and the lower retainer flanges 26 are horizontally aligned with each other, such that they interlock with and hold the cornice molding trim accessory strips 1220 , 1221 in horizontal alignment with each other and in horizontal alignment against a soffit 1208 , FIG. 15 d , over the passage of time to retain an aesthetic appearance, as well as a barrier to weather conditions. Further, the horizontally aligned flanges 23 and 26 will bias the ends of the molding trim accessory strips 1220 , 1221 into horizontal alignment with each other when they have been installed slightly out of alignment. FIG. 15 d discloses an exemplary soffit 1208 against which the cap 1230 and cornice molding trim accessory strips 1220 , 1221 abut. The soffit receiver pocket 115 or 213 of an F-channel cornice receiver strip 113 , 211 , 212 , 311 or 312 receives a rear edge (not shown) of the soffit 1208 . The cap 1230 has a top 11 of sufficiently thin thickness to conform closely to the surface of the lip 94 such that the top 11 wedges between the lip 94 and the soffit 1208 without opening a visibly noticeable gap between the lip 94 and the soffit 1208 .
The cornice molding corner caps 10 , 430 , 1230 of the present invention, in addition to providing aesthetic beauty to an architectural structure, have further functional attributes. The cap is easy to handle and easy to install as a substitute for constructing a finished corner on horizontal ends of the cornice molding made by assembling the cornice receiver strips and the cornice molding trim accessory strips. Further, the cap avoids the need for fasteners at the corner, and solves a problem of how to allow for thermal expansion and contraction of a cornice molding at a corner thereof. The cap, because it is preformed, simplifies the process of finishing corner trim applications. The level of precision of trimming and carpentry work required at the end of a trim strip at a building corner is reduced as the ends of the trim pieces are covered by the corner cap. Caps of the invention can be easily hooked or snapped over the terminal ends of molding strips at the corner of a structure to attain a finished look.
The cap also serves the purpose of closing the cladding on a building structure. The gap at the end of trim strips is effectively covered. This covering prevents or reduces entry of insects and infiltration of water through the gap in the trim strip ends at the edge of a wall having an otherwise more open structure. The receiver channels in the cap allow the cornice molding strips to move freely to expand and contract as necessary with environmental changes such as thermal fluctuations or changes in humidity.
The cap also should resist displacement or dislodgement by forces to which it may be exposed. In windy areas, the cap should remain in place. The cap should not be easily removed or disconnected from the structure unintentionally by impacts.
To test the resistance to displacement, a cornice cap of the invention was mounted on cornice molding strips attached to a wall by an F-channel receiver strips nailed to a pair of strandboard walls having a 90 degree outside corner. The cornice molding strip was Cornice Molding, Product Code 55807, available from CertainTeed Corporation, Valley Forge, Pa. The receiver strip was Deluxe F-Channel, Product Code 52503, available from CertainTeed Corporation, Valley Forge, Pa. These experiments will now be described as Examples 1, 2 and 3. The same cornice molding strips and receiver strips were used in each of the examples. The experiments were carried out at ambient temperatures. These examples are provided to better disclose and teach articles and methods of the present invention. They are for illustrative purposes only, and it must be acknowledged that minor variations and changes can be made without materially affecting the spirit and scope of the invention as described herein.
Example 1
In a first trial, a force gauge with a hook was used to pull the cornice molding, in the absence of a cornice molding corner cap, from the receiver until the molding was dislodged from the receiver. The pulling force was directed perpendicularly away from the wall near the end of the molding strip. The force was measured to remove the molding from the receiver channel.
Example 2
In a second trial, a cornice molding corner cap of the present invention was installed over cornice molding accessory strips mounted to the wall using F-channel receiver strips nailed to the wall. A pushing force was imposed against the cornice molding corner cap at a lateral edge of the cap adjacent to one of the molding strips in a direction parallel to a first molding strip toward the end of the molding strip covered by the cap. The force was applied to the cap until either the cap was dislodged or the second molding strip, perpendicular to the direction of the applied force, was forced out of the receiver strip. A force transducer was used to measure the imposed force through the course of the test. FIGS. 16 a and 16 b depict the test in progress with assembly 500 , FIG. 16 b being slightly later during the test than FIG. 16 . A first cornice molding strip 501 was mounted on the wall by receiver strip 504 . Second cornice molding strip 502 was mounted on the adjacent wall around the corner by receiver strip 507 . Cornice molding corner cap 503 was installed in place over the ends of the two cornice molding strips 501 , 502 . Force transducer 505 was placed in contact with the edge of the corner cap and pushed in a direction indicated by the arrow 506 . The force was applied until the cornice molding strip 502 was dislodged from its receiver strip 507 resulting in the separation gap 508 .
Example 3
In a third trial, a cornice molding corner cap of the present invention was installed over cornice molding accessory strips mounted to the wall using F-channel receiver strips nailed to the wall. A pulling force was imposed on the cornice molding corner cap using a force gauge with a hook fixture attached to the end of the force probe. The fixture was hooked over the top of the cap at the corner to engage a force on the cap. The force was imposed along an angle bisecting the legs of the corner and directly away from the wall. That is to say, the force was directed at an angle of 135 degrees from each of the two walls and in the same plane as the mounting of the two molding strips on the surface of the wall. The force was applied to the cap until either the cap was dislodged or at least one of the molding strips was forced out of its respective receiver strip. FIGS. 17 a and 17 b depict the test in progress with assembly 600 , FIG. 17 b being slightly later during the test than FIG. 17 a . First and second cornice molding strips 601 , 602 were mounted on an outside wall corner 612 having a first wall 610 and a second wall 611 , the walls having a 90 degree angle between the two walls at the corner 612 , by receiver strips 604 . Cornice molding corner cap 603 was installed in place over the ends of the two cornice molding strips 601 , 602 . Force transducer 605 was equipped with hook fixture that was hooked around the top edge of the cap and pulled in a direction indicated by the arrow 606 . The force was applied until the cornice molding strips 601 , 602 were dislodged from their receiver strips 607 resulting in a separation gap between the molding strips and the wall.
The results of the testing of examples 1 through 3 are reported in the table below. The results provided in Table 1 show the estimated forces to dislodge either a cornice molding corner cap or a cornice molding strip.
TABLE 1
Average Force
Example
(lbs)
Type of Displacement
1
7
Cornice molding removed from receiver
2
10
Cornice molding removed from receiver*
3
16
Cornice molding removed from receiver*
*could not measure force to remove cap
The results shown in Table 1 show that once the corner cap is installed, the corner cap is more resistant to displacement than the cornice molding strip itself under application of direct force in either a lateral pushing or pulling mode. Also, when the cornice molding corner cap is in place, it is more difficult to disengage the cornice molding strip from its receiver. The presence of the corner cap provides a more stable mechanical attachment means for the molding strip to the wall, resulting in a more stable trim application. Subsequent tests for blow off resistance under simulated high wind conditions were satisfactory for trim installations employing the cornice molding corner cap of the present invention.
Some dimensional aspects may be helpful in understanding the present invention. While the embodiment portrayed in a number of the figures has a height of about 2.6 inches and an upper face width of about 2 inches, other sizes are useful in accommodating cornice molding trims of various dimensions. Also, the retainer flange dimension requirements, some examples of which have been previously noted, will vary to adapt to the cornice molding strip configuration employed in an assembly, as well as to accommodate differences in flexural modulus of various materials that may be employed in producing the cornice molding corner caps of the present invention. In some embodiments, preferably the upper and lower retainer flanges 23 , 26 are between about 0.05 and 0.5 inch in dimension, more preferably about 0.1 to 0.3 inches.
With respect to thickness of the wall of the corner cap, in one especially preferred embodiment, the thickness of the shell of the main body corner cap is about 0.08 inch as measured at a lateral edge 20 , although some embodiments may have a shell thickness in the range from about 0.01 inch to about 0.3 inch, more preferably from about 0.04 to about 0.1 inches. Thicker shells employ more material can be difficult to flex during installation of the cap. Thinner shells can be more fragile, and more susceptible to damage during handling or in use.
Visual aspects of the molding cap are also important in producing particularly aesthetically appealing embodiments. For example, it is preferred that the gloss be moderately low, so as to avoid excessive sheen or shiny spots when viewing the part at natural viewing angles. It is preferred the gloss be between 5 and 40 measured at 60 degrees, more preferably between 10 and 30, and even more preferably about 20. Both gloss and color should be such that the appearance of the molding cap is aesthetically pleasing when used in combination with a cornice molding strip, the molding strip having its own gloss and color attributes.
Presently preferred materials useful for producing or manufacturing of the cornice molding corner caps are thermoplastic polymers, although thermoset polymers could be employed. Particularly preferred thermoplastics include polyvinyl chloride (PVC) polymers and copolymers, polypropylene (PP) polymers and copolymers, polyethylene polymers and copolymers, acrylonitrile butadiene styrene (ABS) copolymers, acrylonitrile styrene acrylate (ASA) copolymers, acrylonitrile/ethylene-propylene-diene monomer (EPDM) rubber/styrene (AES) copolymers, and mixtures thereof. PVC, PP and ASA polymers are especially preferred, ASA based polymers even more so for darker colored articles, for example articles having a color with a value of L* in the 1976 CIE L*a*b* color scale of less than about 50. Polymer composite materials such as PVC or polyolefin polymers or copolymers filled with wood fiber or flour or a cellulose based fiber may also be employed in corner caps of the present invention. In some embodiments, it is desirable to use a first material having good weatherability as an outer layer on the exterior surface of the corner cap and a second material of lesser durability or weatherability, but providing a balance of more favorable economics or bulk material properties as the main portion of the corner cap body, disposed so as to be protected from the elements by the outer layer. As an example, some embodiments may employ a capstock of an ASA or AES based polymer over a core based on PVC polymers. Another exemplary approach would be to use a core formulated with a polymer having less expensive fillers and a capstock formulated with higher levels of light stabilizers and antioxidants. Recycled materials could be employed in part, or in whole, for such a main portion. Organic or inorganic coatings may also be useful for protective and/or decorative purposes as an outer layer of the corner cap. Such outer layers may be uniform in color or texture or may have variations or variegations for aesthetic effect. Other components useful in producing the corner caps are known in the art such as flow aids, modifiers, heat stabilizers, antioxidants, light stabilizers, colorants, pigments, fillers and the like. Colorants include both pigments and dyes. Light stabilizers include hindered amines and antioxidants include hindered phenols.
A variety of processes can be used to produce cornice molding corner caps of the present invention. These processes include typical ways of forming polymer materials into three dimensional shapes. Such processes include molding, forming, extrusion, coextrusion, compression molding, stamping, vacuum forming, injection molding, coinjection molding, casting, coating, foaming and the like, injection molding and vacuum forming being particularly preferred. Combinations of one or more of the aforementioned processes could also be employed, such as, for example, extrusion or coextrusion followed by vacuum forming or compression molding. Foaming could be with conventional blowing agents, such as chemical or physical blowing agents, or could be a microcellular foaming.
It will be understood that although the elements shown in the figures are relatively plain-surfaced, they may be shaped and decorated in any desired manner consistent with their interrelational functioning as described herein. Such decorations could include colors, appliqués, beveling, molding, shaping and the like, or other aesthetic treatments.
It will also be understood that by inverting the face of the structure through a symmetry plane transecting the corner of the cornice molding corner cap, an inside corner may be produced. That is to say that the angle between the decorative exterior faces of the corner cap could be about 90 degrees, rather than the approximately 270 degree angle shown in some of the figures included with this specification. In such an inside corner cap, the angle between the inside faces of the cap could be about 270 degrees as compared with the angle shown in some of the drawings being about 90 degrees. An inside corner could involve an angle of 90 degrees, or some other angle as desired for matching architectural detail, for example, having a larger angular sweep in a bay window area application, or a smaller angular sweep in an acute angular architectural detail. Similarly, the angle of an outside corner piece according to the invention could take on a range of values to accommodate architectural features encountered in a building structure.
Various other modifications can be made in the details of the various embodiments of the processes, compositions and articles of the present invention, all within the scope and spirit of the invention.
This description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.
Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention. | A method of using an assembly and a method of finishing an uppermost course of siding installed at a corner of a building with a cornice molding. A cornice molding cap is provided as an accessory to cover or eliminate gaps created where cornice molding meets at a corner of a building. The cap covers gaps where cornice molding meets at a corner structure formed by two walls. The cap is particularly useful in exterior siding installations at corners not employing corner posts having receiver pockets for cladding material end edges. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of U.S. provisional patent application Serial No. 60/366,237 filed Mar. 22, 2002.
FIELD OF THE INVENTION
[0002] The present invention generally relates to specific combinations of active particles, forming a powder, that may be combined with carrier materials such as resins to produce fibers for textiles, films, coatings, and/or protective or insulating materials. The specific mixture of particles and materials may be engineered to impart unique and valuable properties to end products, including integration with optical energies, heat, and other electromagnetic energies. Resultant compositions may interact with light in the visible spectrum, as well as optical and electromagnetic energy beyond the visible spectrum.
[0003] The powder may be added to a carrier material, such as, for example, a polymer, which may then be extruded to form a fiber or formed into a membrane, or film, which may be used to create a fabric or coating useful in a variety of applications. Such applications may include hosiery, footwear, active wear, sports wear, sports wraps, base layer, gloves, and bandages. These items may also have certain properties such as controlling odor, regulating heat, providing protection from fire, providing protection from harmful light, insulation, wound healing, and preserving food. The powder may be designed to interact in a benign manner with the human body, its needs, requirements, and homeostatic stabilization.
BACKGROUND OF THE INVENTION
[0004] Human bodies, as well as other organisms and substances, produce electromagnetic radiation in the form of, for example, heat or infrared radiation. In certain circumstances it may be desirable to retain this radiation, such as, for example, applications in which maintaining body heat or food temperature is desired. For example, once a food product is cooked, it may reach a certain temperature; however, this heat is often lost by exposure to cooler temperatures such as ambient air. In another example, a human body may be exposed to cooler temperatures, and infrared radiation may be lost through the epidermis. Retaining this infrared radiation, may have certain beneficial properties including maintaining a particular temperature, evading detection by infrared sensors, insulating pipes and other construction materials to prevent heat transfer, and providing heat to prevent joint stiffness. Known fibers do not completely solve the escape of radiation from a heat-emitting object, without also creating moisture or other undesirable side effects.
SUMMARY OF THE INVENTION
[0005] This invention seeks to correct the problems and meet the needs of the industry as detailed above. Therefore, it is a specific objective of the present invention to provide methods and compositions that will provide a biologically benign composition that is optically responsive.
[0006] One embodiment of the invention relates to a composition comprising titanium dioxide, quartz, aluminum oxide, and a resin. The resin composition is a polymer. The aluminum oxide, titanium dioxide, and quartz may be dispersed within the resin. In addition, the titanium dioxide, quartz, and aluminum oxide may be present in a dry weight ratio of 10:10:2, respectively. In this embodiment, the titanium dioxide, quartz, and aluminum oxide may comprise about 1 to about 2 percent of the total weight of the composition, and the composition may be biologically benign.
[0007] In another embodiment of the present invention, the titanium dioxide within the composition may comprise an average grain size of about 2.0 microns or less and the grains may be substantially triangular. The aluminum oxide within the composition may comprise an average grain size of about 1.4 microns or less and the grains may be scalloped-shaped. Additionally, the quartz within the composition may comprise an average grain size of about 1.5 microns or less and the grains may be rounded in shape. The titanium dioxide, aluminum oxide, and quartz composition may be homogenized within this embodiment of the present invention. In addition, the composition may shift the wavelength of incident light, by both shortening and lengthening the wavelength of the incident light that is exposed to the composition.
[0008] The invention herein also relates to methods for creating an optically responsive yarn comprising the steps of extruding the composition of the above mentioned embodiments into a plurality of fibers and spinning those fibers into yarn. The present invention may consist of woven fibers comprising the aforementioned composition. In an alternative embodiment, the composition may also be woven with fibers comprising one or more additional natural fibers such as wool, cotton, silk, linen, hemp, ramie, and jute. In yet another embodiment, the composition may also include woven fibers comprising one or more synthetic fibers such as acrylic, acetate, lycra, spandex, polyester, nylon, and rayon. The present invention may also consist of non-woven fibers comprising the aforementioned composition. The non-woven fibers may be spun with woven natural fibers such as wool, cotton, silk, linen, hemp, ramie, and jute, or synthetic fibers such as acrylic, acetate, lycra, spandex, polyester, nylon, and rayon. The optically responsive yarn can be produced by these methods to create a fabric comprising either the woven or non-woven fibers of the aforementioned composition, spun together with a plurality of natural, synthetic or both natural and synthetic fibers.
[0009] Yet another embodiment of the present invention herein also relates to methods of retaining source radiation emitted from a subject or object comprising covering or surrounding an object bodily area with one of the above mentioned fabrics. In this embodiment, the fabric may be comprised of woven fibers consisting of the aforementioned composition. The composition spun with the woven fibers may be either natural or synthetic. The radiation may also be infrared radiation.
[0010] The present invention also relates to methods of retaining source radiation emitted from an object and may be achieved by covering or surrounding the object with one of the above mentioned fabrics.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] It is understood that the present invention is not limited to the particular methodology, protocols, and reagents, etc., described herein, as these may vary. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise.
[0012] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. Preferred methods, devices, and materials are described, although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention. All references cited herein are incorporated by reference in their entirety.
[0013] The present invention focuses on the creation of and methods of use of a biologically benign powder in a resin that has certain beneficial properties such as retaining source infrared radiation and changing the wavelength of light reflected by the powder or passing through the powder. This powder may be combined with a carrier material, such as a resin, specifically a polymer, and/or implemented into a textile fiber, a non-woven membrane, or a similar product. Products that incorporate this powder may provide additional beneficial properties to a subject wearing such a product such as, for example, wound healing, skin fibroblast stimulation, fibroblast growth and proliferation, increased DNA synthesis, increased protein synthesis, increased cell proliferation by changing the optical properties in and around the human system interacting with light, and changing the wavelength, reflecting, or absorbing light in the electromagnetic spectrum. The compositions and fibers of the present invention represent a combination of substances that work together with electromagnetic radiation to provide such beneficial properties.
[0014] Additionally, the compositions of the present invention may be used in a variety of settings to trap source infrared radiation, to provide heat to an object, or to prevent the escape of infrared light. Some uses may include, but are not limited to, insulation of heating and cooling systems, thermal insulation for outdoor recreation, retention of infrared light by military forces to prevent detection, and insulation of perishable items. Other uses of a fabric made from such a composition include hosiery, footwear, active wear, sports wear, sports wraps, base layer, gloves, and bandages. These items may also have certain properties such as controlling odor, regulating heat, providing protection from fire, providing protection from harmful light, insulation, wound healing, and preserving food.
[0015] Electromagnetic light spans a very large spectrum from 10 nm to 1060 nm of wavelength and spans ultraviolet light, visible light, and infrared light. Ultraviolet (“UV”) light has wavelengths from 10 nm to 390 nm and is divided in to near (390 to 300 nm), mid (300 to 200 nm), and far (200 to 10 nm) spectra regions. Visible light is a small band in the electromagnetic spectrum with wavelengths between 390 and 770 nm and is divided into violet, blue, green, yellow, orange, and red light. Infrared (“IR”) light spans from 770 nm to 1060 nm and includes near (770 to 1.5×10 3 ), mid (1.5×10 3 to 6×10 3 ), and far (6×10 3 to 10 6 ) regions. The refractive index (“RI”) is a measure of a substance's ability to bend light. Light and optical energy that the body is exposed to extends throughout the electromagnetic spectrum. The adult human body, at rest, emits about 100 watts of IR in the mid and far wavelengths. During exercise this level rises sharply and the distribution of wavelengths changes.
[0016] There are many types of materials that interact with optical energy by absorbing, reflecting, refracting, and/or changing the wavelength. When light is absorbed it is changed into molecular motion or heat, or optical energy of a longer wavelength. In one embodiment, the present invention relates to a material, such as a resin, film, polymer or fiber, for example, that is optically responsive to light and electromagnetic spectrums. The end materials created may be used to interact with living or non-living systems. The end material may be created by adding various active materials together to form a powder. The powder may then be combined or mixed with carrier materials that may have their own unique optical properties and may also act as a matrix for the powder and its particles.
[0017] The active materials selected to form the powder are selected based upon several characteristics. One characteristic is that the active materials, in particle form, may be biologically benign, or inert. The material preferably exhibits one of two optical properties: being transparent or having a different refractive index than the carrier material. Specific active materials that may be used in the present invention include silicon, carbon, and various vitreous glasses including oxides of aluminum, titanium, silicon, boron, calcium, sodium, and lithium. In a specific embodiment, the active materials are titanium dioxide, quartz, and aluminum oxide.
[0018] For example, the choice of materials and their optical properties can be selected to effect a certain result, such as, for example, a biological excitation for a range of wavelengths from 1.015 microns to 0.601 microns (601 nm). To target this area of light, an overlapping series of pass-bands that promote excitation and emission in the ranges that bracket the desired wavelength may be created by the materials. These pass bands may be created by using particles of staggered refractive indices with respect to the host, creating a known transparency and if possible concentrating normally blocked or attenuated wavelengths by using particles with high transparency and moderate refractive indices. Additionally, to ensure wide excitation, a material that is transparent to UV light with a high refractive index that is not transmissive at short wave, or harmful, UV regions may be used.
[0019] Specific carrier materials that may be used in the present invention include resins such as rayon, polyester (PET), nylon, acrylic, polyamide, and polyimide. For applications related to infrared light, solid transparent materials with a transmission in the range, of about 0.5 to about 11 microns is preferable, such as, for example, polyethylene and many of its derivatives, polypropylene and many of its derivatives, polymethylpentene, and polystyrene and many of its derivatives. These materials may also exhibit useful transparencies in the ultraviolet. The addition of active particles with varying refractive indices may yield a wide range of filtering effects in the IR and UV ranges. In particular, PET may serve as a medium to encase and act as a lensing medium for active materials.
[0020] Once the materials are selected, they may be ground or processed to comprise various properties. The grinding or processing helps to determine the particle size of the active material, the concentration of each type of active material, and the physical characteristics of the active material, and is known in the art. The physical characteristics may include the smoothness or shape of the particles. For example, the particles may be smooth, round, triangular, or scalloped.
[0021] The end material may achieve one of two results with respect to wavelength: it may shorten or lengthen wavelength depending the desired effect. In either use, IR light excites atomic and/or molecular structure. The excitation may frequently result in stresses on either atomic or molecular levels. When the stress is released, the electron energy level may change and release energy as photons.
[0022] In some combinations of carrier and active particle materials, particular wavelengths may be selected by the ease that a given wavelength may be absorbed and/or emitted. If the active particles are suspended in a matrix that performs a filtering action, i.e., passing optical energy, the active particles may be closer to the wavelength of the carrier material. Conversely, if shorter or longer wavelengths are to be passed, the size of the active particles may be closer to the size of the wavelength of the light passed. For example, in applications in which the desired wavelength is 1 micron, the particle size may be the same, i.e., 1 micron. If carrier material, such as PET for example, is capable of passing 14 micron to 4 microns it may be desirable to have some particles slightly larger than or equal to those wavelengths. Desired particles sizes may range from about 2 microns to about 0.5 micron and are preferably related to the targeted wavelength.
[0023] In a specific embodiment, the powder may comprise aluminum oxide (Al 2 O 3 ), quartz (SiO 2 ), and titanium dioxide (TiO 2 —in rutile form). Titanium dioxide may be obtained from any commercially available source, such as from Millennium Chemicals, Inc., Hunt Valley, Md. Quartz may be obtained from any commercially available source, such as Barbera Co., Alameda, Calif. Aluminum oxide may be obtained from any commercially available source, such as from Industrial Supply, Loveland, Colo.
[0024] Aluminum oxide has a unique property that promotes infrared light bandshifts under certain conditions. When aluminum oxide is combined with other materials, such as those described herein, interaction with IR light occurs. For example, the IR light emission of the human body is absorbed and excites electron energy levels in the atoms and molecules of the components of the compositions of the present invention. As the electrons return to their previous energy levels they release energy in the IR range but at a different wavelength, i.e., a longer Wavelength. The compositions of the present application, when used in a body covering, such as a compression wrap or sleeve, utilize these bandshifting properties of aluminum oxide to reflect longer infrared wavelengths back into the human body. The longer infrared wavelength, for example, allows capillaries to relax and be less constricted, resulting in greater blood flow where required, which results in improved body circulation.
[0025] Quartz, or silicon dioxide, is biologically benign if it is incorporated into a carrier material in solid bulk form. Quartz is also capable of non-linear frequency multiplication, and, in proper combination with a particular wavelength and a carrier, may emit ultraviolet (UV) light. UV light is known to inhibit bacterial growth and the creation of ozone. UV that has a wavelength that is too short can be detrimental to the human system. Quartz may be used to absorb the shorter wavelength UV light if its physical particle size is close to the wavelength of light that should be excluded. In the present invention, quartz may be used to increase frequency or shorten wavelength.
[0026] In addition to being optically active, quartz may exhibit piezoelectric properties. When quartz is stressed, the distribution of charges may become unequal and an electric field may be established along one face and an opposite field may be established along the other face. If the stressing effect, such as pressure, for example, is constant, the charges may redistribute themselves in an equal and neutral manner. If the stress is removed once the charges are redistributed, a charge of opposite polarity and equal magnitude to the initial charge may be established. This charge redistribution results in nonlinear behavior, which may be manifested as frequency doubling.
[0027] Titanium dioxide is unique because it has a high refractive index and also has a high degree of transparency in the visible region of the spectrum. It is used as a sunblock in sunscreens because it reflects, absorbs, and scatters light and does not irritate the skin. Only diamonds have a higher refractive index than titanium dioxide. For these reasons, titanium dioxide is ideal for applications that are close to skin surfaces.
[0028] If the optical properties of titanium are used in conjunction with quartz and an appropriate carrier material, such as PET, for example, a greenhouse effect may be created. Infrared wavelengths of one size may pass back through the PET and may be reflected. This reflection creates longer wavelengths that prevent passage back through the PET. In a specific embodiment of the present invention this property may be used to reflect longer wavelengths into the human system while directing shorter, more harmful wavelengths away from the human system.
[0029] Particle size and shape of the active materials in the powder may also affect the end product by controlling the wavelength of light that is allowed to pass through the particles. In a specific embodiment, a particle size of about 1.4 microns or smaller is used for aluminum oxide. The particle shape may be scalloped. The particle size of quartz may be about 1.5 microns or smaller. The quartz particles may be spherical or substantially spherical. The titanium dioxide particles may be about 2 microns or smaller and triangular with rounded edges.
[0030] The specific properties and characteristics of the active particles and carrier materials may be combined to produce a specific effect such as wound healing, skin fibroblast stimulation, fibroblast growth and proliferation, increased DNA synthesis, increased protein synthesis, and increased cell proliferation by changing the optical properties in and around the human system. These properties are related to specific wavelengths of light and the interaction of that light with the compositions of the present invention.
[0031] In one embodiment of the present invention wavelengths may be selected to provoke melanin excitement, which occurs at about 15 nm. To achieve this excitement an energy range from a band about 10 nm to about 2.5 microns from the human metabolic action may be used. Daylight from either an outdoor broadband or an indoor lamp ranges from about 1.1 microns, with a “hump” around 900 nm and a broad general peak around 700-800 nm, and also includes lesser wavelengths such as 400 to 700 nm. Some of the general properties and desirable filtering and changes include but are not limited to having band pass in the 600 to 900 nm band range. Also, a carrier material may be selected to have a transparency from 200-900 nm. PET has a known transparency in the 8 to 14 micron range. An active particle may also be selected to have a wavelength between about 950 and 550 nm. This may be accomplished by using particles with a general size distribution of 2 microns and lower.
[0032] Muscle and bone atrophy are well-documented in astronauts, and various minor injuries occurring in space have been reported not to heal until landing on Earth. Spectra taken from the wrist flexor muscles in the human forearm, and muscles in the calf of the leg, demonstrate that most of the light photons at wavelengths between 630-800 nm travel 23 cm through the surface tissue and muscle between input and exit at the photon detector. The light is absorbed by mitochondria where it stimulates energy metabolism in muscle and bone, as well as skin and subcutaneous tissue. Evidence suggests that using LED light therapy at 680, 730 and 880 nm simultaneously in conjunction with hyperbaric oxygen therapy accelerates the healing process in Space Station missions, where prolonged exposure to microgravity may otherwise retard healing. Tissues stimulate the basic energy processes in the mitochondria (energy compartments) of each cell, particularly when near-infrared light is used to activate the color sensitive chemicals (chromophores, cytochrome systems) inside each cell. Optimal LED wavelengths may include 680, 730, and 880 nm. Whelan et al., 552 SPACE TECH. & APP. INT'L FORUM 35-35 (2001). Whelan et al., 458 SPACE TECH. & APP. INT'L FORUM 3-15 (1999). Whelan et al., 504 SPACE TECH. & APP. INT'L FORUM 37-43 (2000). Near-infrared light at wavelengths of 680, 730 and 880 nm stimulate wound healing in laboratory animals, and near-infrared light has been shown to quintuple the growth of fibroblasts and muscle cells in tissue culture. Hence, the particle size of the compositions of the present invention may be selected to provide reflective or pass through beneficial wavelengths of light.
[0033] The active particles of the present invention may be ground to reach an approximate particle size of about 0.5 to about 2.0 microns. For example, titanium dioxide may be ground to a grain size of between 1 and 2 microns and may be triangular with rounded edges. Aluminum oxide may be ground to a grain size of between 1.4 and 1 microns and may be scalloped-shaped. Quartz is preferably ground to a grain size of about 1.5 to 1 microns and is generally rounded. All particles are reduced in size and shaped by processes known in the art, such as grinding, polishing, or tumbling, for example. In a preferred embodiment, the dry weight ratio of the active materials titanium dioxide, quartz, and aluminum oxide in the powder is 10:10:2, respectively.
[0034] In a specific embodiment of the present invention, the compositions may further comprise a resin, such as a polymer made into a film or fiber. The polymer may initially be in pellet form and dried to remove moisture by using, for example, a desiccant dryer. The powder may then be dispersed into the resin by methods known in the art, such as for example in a rotating drum with paddle-type mixers. In one embodiment of the present invention the polymer used may be polyester. The powder may comprise from about 0.5 to about 20 percent of the mixture. In another embodiment, the powder may comprise from about 1 to about 10 percent of the mixture. In a specific embodiment, the powder may comprise from about 1 to about 2 percent of the total weight of the resin/powder mixture. To produce one half ton of fiber, about 100 pounds of the powder may be combined with about 1000 pounds of PET. In an alternative embodiment, the powder may be introduced to the resin by other processes known in the art such as compounding, for example. In this embodiment, 100 pounds of the powder may be combined with about 250 to about 300 pounds of PET.
[0035] After the resin and powder are combined, the resulting liquid may be extruded into fiber that may be drawn into staple fibers of various lengths. This process of grinding, combining, and extrusion is known in the art, as described in, for example, U.S. Pat. Nos. 6,204,317; 6,214,264; and 6,218,007, which are expressly incorporated by reference in their entirety herein.
[0036] The basic techniques for forming polyester fiber by extrusion from commercially available raw materials are well known to those of ordinary skill in this art and will not otherwise be repeated herein. Such conventional techniques are quite suitable for forming the fiber of the invention and are described in U.S. Pat. No. 6,067,785, which is herein expressly incorporated by reference in its entirety.
[0037] After extrusion the fibers may be combined together by a spinning process, preferably using a rotary spinning machine, to yield a yarn. The range of the size of the apertures in the rotary spinning machine may be from about 6 microns to about 30 microns.
[0038] In preferred embodiments, the step of spinning the fibers of the present invention into yarn comprises spinning staple having a denier per fiber of between about 1 and about 3; accordingly, the prior step of spinning the melted polyester into fiber likewise comprises forming a fiber of those dimensions. The fiber is typically heat set before being cut into staple with conventional techniques. While the extruded fibers are solidifying, they may be drawn by methods known in the art to impart strength.
[0039] Similarly, the method can further comprise forming fabrics, typically woven or knitted fabrics from the spun yarn in combination with both natural and synthetic fibers. Typical natural fibers may include cotton, wool, hemp, silk, ramie, and jute. Alternatively, typical synthetic fibers may include acrylic, acetate, Lycra, spandex, polyester, nylon, and rayon.
[0040] Because polyester is so often advantageously blended with cotton and other fibers, the present invention also includes spinning a blend of cotton into yarn in which the polyester may include between about 0.5 and 4% by weight of polyethylene glycol into yarn in a rotor spinning machine.
[0041] The method can further comprise spinning the fibers of the present invention. Similarly, the fibers of the present invention may include a woven or knitted fabric from the blended yarn with the yarn being either dyed as spun yarn, or after incorporation into the fabric in which case it is dyed as a fabric.
[0042] The cotton and polyester can be blended in any appropriate proportion, but in the specific embodiments the blend includes between about 35 and 65% by weight of cotton with the remainder polyester. Blends of 50% cotton and 50% polyester (“50/50”) are also used.
[0043] The yarn formed according to this embodiment can likewise be incorporated into blends with cotton, and is known to those familiar with such blending processes, the cotton is typically blended with polyester staple fiber before spinning the blend into yarn. As set forth above, the blend may contain between about 35% and 65% by weight cotton with 50/50 blends being typical. Other methods of production of fibers are equally suitable such as those described in U.S. Pat. Nos. 3,341,512; 3,377,129; 4,666,454; 4,975,233; 5,008,230; 5,091,504; 5,135,697; 5,272,246; 4,270,913; 4,384,450; 4,466,237; 4,113,794; and 5,694,754, all of which are expressly incorporated by reference in their entirety herein.
[0044] In one embodiment of the present invention, the polyester mixture may be used to create a staple fiber. The staple fiber may then be used to create a non-woven membrane. This membrane may be bonded to another fabric, membrane or material. For example, the non-woven membrane may be used as a lining by being bonded to the inside of a pair of leather gloves or, for example, being bonded to another fabric such as ThinsulateTM by 3M by methods known to those skilled in the art.
EXAMPLES
[0045] Without further elaboration, it is believed that one skilled in the art, using the preceding description, can utilize the present invention to the fullest extent. The following examples are illustrative only, and not limiting of the remainder of the disclosure in any way whatsoever.
Example 1
Thermal Homeostasis
[0046] Two batches of wrist bands are prepared: WB1 (woven with fibers comprising the powder composition of the present invention) and WB2 (woven with fibers lacking the powder composition of the present invention).
[0047] Twenty panelists are selected from the general population, and no specific demographic parameters are utilized in recruiting the panelists. Panelists are placed within a climate-controlled area of standard room temperature, standard humidity, and sea-level atmospheric pressure. A measurement of each panelist's middle finger temperature is taken prior to the panelists' donning of any band. Panelists are asked to don a band from WB2. Five minutes later, a measurement of each panelist's middle finger temperature is taken. Panelists are then asked to remove the band from WB2, wait five minutes, and don a band from WB1. Five minutes later, measurements of each panelist's middle finger temperature are taken. Thermographic instruments are used to record the temperatures of the fingers of the panelists throughout the trials. All temperature measurements are averaged.
[0048] There exists a statistically significant difference between the average middle finger temperature of the panelists after their donning of bands from WB1 and the average middle finger temperature of the panelists prior to their donning of any band. Further, there exists no statistically significant difference between the average middle finger temperature of the panelists after their donning of bands from WB2 and the average middle finger temperature of the panelists prior to their donning of any band. The ability of the bands woven with fibers comprising the powder composition of the present invention to serve as agents of thermal homeostasis is demonstrated.
Example 2
Muscle Strength
[0049] Two batches of wrist bands are prepared: WB1 (woven with fibers comprising the powder composition of the present invention) and WB2 (woven with fibers lacking the powder composition of the present invention).
[0050] Panelists are selected from the general population, and no specific demographic parameters are utilized in recruiting the panelists. Panelists are placed within a climate-controlled area of standard room temperature, standard humidity, and sea-level atmospheric pressure. A measurement of each panelist's grip strength is taken prior to the panelists' donning of any band. Panelists are asked to don a band from WB2. Five minutes later, a measurement of each panelist's grip strength is taken. Panelists are then asked to remove the band from WB2, wait five minutes, and don a band from WB1. Five minutes later, measurements of each panelist's grip strength are taken. Grip dynamometers are used to record the grip strengths of the panelists throughout the trials. All grip strength measurements are averaged.
[0051] There exists a statistically significant difference between the average grip strength of the panelists after their donning of bands from WB1 and the average grip strength of the panelists prior to their donning of any band. Further, there exists no statistically significant difference between the average grip strength of the panelists after their donning of bands from WB2 and the average middle finger temperature of the panelists prior to their donning of any band. The ability of the bands woven with fibers comprising the powder composition of the present invention to increase muscle strength is demonstrated.
Example 3
Insoles
[0052] The powder composition of the present invention is prepared by the processes of the present invention. Two batches of insoles are prepared: IN1 (woven with fibers comprising the powder composition of the present invention) and IN2 (woven with fibers lacking the powder composition of the present invention).
[0053] Panelists are selected from the general population, and no specific demographic parameters are utilized in recruiting the panelists. Samples, are presented to panelists in a blinded manner (samples are identified only by a random digit label). Each panelist receives two insoles to wear, one within each shoe, and panelists are instructed to randomly place one insole within each shoe. Thus, the shoe (right or left) in which each insole is worn is completely random. In each pair of insoles, one sample is from IN1 and one sample is from IN2. Panelists are asked to record any differences between the two insoles that they notice after wearing them for an eight hour period.
[0054] A number of the panelists note a difference between the insoles. A statistically significant number of those panelists noting a difference between the two insoles regard the insole comprising the powder composition of the present invention as providing greater comfort than the insole lacking the powder composition of the present invention. The ability of the insoles woven with the fibers comprising the powder composition of the present invention to provide comfort is demonstrated.
[0055] Various modifications and variations of the described methods and systems of the invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in materials engineering or related fields are intended to be within the scope of the following claims. | The present invention generally relates to specific combinations of active particles, forming a powder, that may be combined with carrier materials such as resins to produce fibers for textiles, films, coatings, and/or protective or insulating materials. The specific mixture of particles and materials may be carefully engineered to impart unique and valuable properties to end products including integration with optical energies, heat, and other electromagnetic energies. Resultant compositions may interact with light in the visible spectrum and optical and electromagnetic energy beyond the visible spectrum. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of pending International patent application PCT/FR2006/002895 filed on Dec. 22, 2006 which designates the United States and claims priority from French patent application 0513252 filed on Dec. 23, 2005 and 0600018 filed on Jan. 3, 2006, the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to techniques for visiometric examination applied to objects arranged for examination in defined discrete locations and in successive rows, in a continuous series following a regular spatial distribution that is repeated periodically. The concept of visiometric examination is taken here as including all techniques of the optoelectronic type that involve the capture of an image that detects a light beam coming from each object submitted to examination under incident rays, as well as an analysis by image processing on the received signals, controlled by adapted software, in order to deduce the condition of the examined objects in terms of established characteristics. In addition, the concept of object, in the context of this invention, covers what will appear later as an absence of object. In other words, the objects to be considered are instead considered locations, since it is understood that these locations correspond to the aforementioned relative arrangement that is periodically repeated in successive rows.
BACKGROUND OF THE INVENTION
In the following text, various applications of the invention are described, with more specific reference to its preferred applications in the field of the food industry for candling eggs. The locations subjected to radiation examination in this case are, in practice, the various cells of the egg crate grid in which the eggs are arranged, each being held in one of the cells. In addition, the egg candling operations, as they are currently practiced at an intermediate stage in the production of chicks for chicken eggs, between an incubator and a hatching device, are intended to examine the eggs by transparency by submitting them individually to a light beam, usually of infrared light, in order to establish a distinction between the eggs based on the state of fertilization of each, and thus to allow selection of those that have been fertilized while excluding those that have not been fertilized, with the fertilized eggs being sent to the hatching devices where the chicks are born. Specifically, each egg is characterized as fertilized or non-fertilized according to the diminution in a light beam to which it is exposed. However, whether this is done for eggs, for any other type of product in individualized units, or even for discrete locations made up of adjacent zones of a contained product, it will obviously be possible for the professional to transpose the vocabulary to apply the invention to other criteria of discrimination and selection, as well as other industrial areas.
In conventional egg candling installations, including those described in particular in patent application WO 99/14589 (Ecmas) or in the American U.S. Pat. No. 5,900,929 (Embrex), the practice is to process the egg crate grids in series, each grid containing a batch of eggs. Generally, direct use is made of crate grids used for incubating eggs. Eggs are placed therein in cells arranged in locations at regular intervals, in each egg crate grid, following a repeated pattern of longitudinal lines and latitudinal rows. The grids are placed successively horizontally over a conveyor appliance (for instance, of the conveyor belt type that rotates in a closed circuit), which conveys them through the optoelectronic examination site.
In this site, a radiating source emits an incident light flow that illuminates each of the eggs individually. When dealing with an application aimed at locating the air chamber inside the eggs, these means of illumination for the eggs are arranged on the same side as the detectors that receive the light emerging from the eggs and determine its composition according to the modification caused by each of them. The same would be true if, for instance, the application consisted in examining the coloring of fruits that were individually maintained, instead of eggs, in the cells of similar crate grids. However, in the more common application, i.e. egg candling, aimed at distinguishing fertilized eggs from those that are to be removed from the particular series, as in our example here, the source is generally placed below the conveyor circuit of the crate grids, to produce illumination from below to above toward the detecting appliances located above. It is advantageous but not obligatory to use a light that lies within the range of the infrared wavelength.
For detection methods that are sensitive to the emerging flow, one can use either individual sensors that are associated with each egg respectively, or preferably a video camera. When the detected light intensity descends below a predetermined threshold, indicating an attenuation threshold that can be computed in known manner depending on the diffusion properties of the eggs or determined experimentally, indicating the presence of an embryonic germ, and the system is instructed to automatically designate the examined eggs as being fertilized. The cell structure of the incubation crate grids is naturally adapted to optical examination. In general, the cells are bottomless, for examination by transmission, and they maintain the eggs with the large vertical axis, which lends itself well to an examination that is advantageously produced in the vicinity of this large axis.
The locations in lines and rows, especially for the cells that receive eggs, are most commonly configured with square patterns, or triangular, or particularly hexagonal patterns, in the style known as quincunx. Quincunx arrangements differ from those in square patterns in that, from one row to the next, the cells are no longer aligned in the longitudinal moving direction, but are offset laterally. For instance, if the offset distance can be any fraction of the pace of distribution of the cells within each row, the most frequent quincunx arrangement corresponds to a displacement of a half-step in a regular distribution of the hexagonal type.
In addition, the means of illumination and the associated means of detection are arranged and controlled to match the spatial configuration of the cells of the crates. In industrial applications, an optimal compromise between cadence of the processing, reliability of the sorting, costs of installation and operation requires simultaneous operation on a group of locations of eggs in repetitive manner in the course of the passage through a visiometric examination point in which the material remains stable. This means that in general, the examination takes place row by row as the successive rows pass under the detectors. From this point of view, the invention foresees, as will be explained further hereafter, examination of the displaced rows of the quincunx arrangements by considering them grouped together in order to use the same means of illumination and means of detection, for instance on the even numbered row and the odd numbered row in each pair of rows of a hexagonal arrangement.
In a preferential manner, the analysis by visiometric analysis aimed at detecting the presence of fertilized eggs takes place at the entry to the egg-candling installation. The crates are placed manually or automatically on the conveyor device, for instance a conveyor on a rotating belt in closed circuit, which takes them through the visiometric examination site. On leaving said site, the installation is advantageously supplemented by a marking station, where the eggs are marked selectively so that they are transferred thereafter toward distinct reserved destinations, depending on whether they are fertilized or not. The sorting is generally carried out manually to eliminate from the chain the non-fertilized eggs, but it can also be performed automatically by a supplementary apparatus.
The invention aims to improve the conditions for industrial exploitation of such egg-candling installations, principally concerning the reliability of the detection of the state of fertilization of the eggs and the cadence of processing. Especially in the case of an installation in which the egg crates are treated linearly in a marking station after the visiometric examination station, the problem arises of being able to mark the eggs efficiently and rapidly by directly utilizing the signal produced by numerical processing of the images captured by the visiometric examination while taking care not to risk breaking the egg shells. In the same concern for processing at high cadence in full security in the selection of the eggs depending on their state of fertilization, it is useful to find a solution to difficulties that appear at the visiometric examination station where more than two conditions are to be distinguished for each location of the entire group that is passing through, especially if in some rows of eggs certain cells have remained empty accidentally.
SUMMARY OF THE INVENTION
Considering one of these aspects, the present invention takes note of the fact that the means of attenuation of the light beams can be strongly disturbed by phenomena of reflection of the sensors of the video camera when the luminous flows that must be detected at one and the same instant are at levels of intensity too different and for this reason lead to false information concerning the condition of the eggs examined. This situation arises frequently, for example in the presence of a rotten egg or of an empty cell among the clear, fertilized eggs. It is clear here that the absence of egg in a cell, allowing passage of the entire luminous flow, is indicated by an illumination of very great intensity, much higher than when an egg is present there, no matter what its condition may be. At the same time, when the egg present in a particular cell is a clear egg, it attenuates the luminous flow passing through it very little, but the attenuation of this flow is noticeably stronger for an egg with false seed, a fertilized egg, a rotten egg, these three cases being cited here in the order of the growing attenuations.
As a non-restricting example, the diagram in FIG. 3 , appended to this description, schematically illustrates the sale of luminous intensities/captured by the detection video camera. The intensities include three very distinct ranges of luminous intensity:
G 1 : very high illumination corresponding to the case “absence of egg” (intensity I 1 ); G 2 : high illumination corresponding to the case “clear egg” (intensity I 2 ); G 3 : weak illuminations corresponding to cases “false germ” (intensity I 3 ), “fertilized egg” (intensity I 4 ), and “rotten egg” (intensity I 5 ).
In view of the presence of this very wide range of luminous intensities, there is the risk of “glaring” of the video camera sensor. In fact, modern apparatuses most often use a monolithic sensor with semiconductors of the “CCD” type (meaning “Charge Coupled Device”). This type of sensor can consist of a chain of photo detector or photo site elements. These photo detectors convert the captured light into electric signals. They in turn are aligned on the chain parallel to the rows of cells and they function simultaneously for all the cells of each row passing through the visiometric examination site. If the photon flow striking one of the photo detectors is excessively energetic, the aforementioned glaring phenomenon appears, as can be seen from a parasitic diffusion of electrons toward the neighboring photo detector elements. The most disturbing result in the chick production industry can be, for instance, that the absence of an egg in one cell falsifies the result for neighboring cells and that for each of these cells, even if an egg is present, it is impossible to distinguish whether it is fertilized or not. In other words, this condition can cause a dysfunction of the processing series of the signals (processing carried out by the automatic analysis apparatus), and eventually may result in preventing correct differentiation between conditions of transparency presented by eggs in cells belonging to the same row as the cell that caused the error and which are examined at the same time.
In the current state of the art, it is thus necessary to discard all the eggs in this row, which naturally causes waste and financial losses that should be avoided. In the case of an industrial application, it is not thinkable to stop the detection procedure, since the sorting goes on at a very fast rate or cadence, typically on the order of 6,000 eggs per hour.
It could seem sufficient to contract or attenuate the scale of luminous intensities to avoid this phenomenon, while attenuating the maximum level of luminous intensity (absence of egg: intensity I 1 ). However, it has been observed that the range G 3 is made up of levels of luminous intensity that are relatively close to one another. This can make it difficult to discriminate between the three levels of this range. To obtain a good contrast and to be capable of making this discrimination, it is necessary to resort to a relatively strong illumination dosage, which causes an expansion of the range G 3 , but also correlatively over the complete range of intensities and thus the maximum illumination level, causing increased risk of glare. In a more general case, it is possible to encounter any number of ranges of levels of luminous intensity that are quite far apart from one another. And as in the case of egg candling, the ranges of sensitivity of the examination by luminous radiation are often closer to a range of the logarithmic type that to a proportional range.
It therefore becomes necessary to be able to avoid risks of glare for the detection sensor, while preserving the possibility of fine discriminations between light intensities at levels relatively close to one another, that is, to avoid a strong contrast, which seems completely contradictory.
The invention aims to overcome the disadvantages of apparatuses known in the art. It therefore proposes to conduct the visiometric examination of each row in successive stages (at least two), illuminating the batches for examination by illumination doses that are set differently from one stage to the other between two successive stages, and in a second stage illuminating only those batches that, in a first stage, were not shown to present a condition that would cause glaring of the sensor in the second stage.
In particular, the invention takes the form, in terms of procedure, of an analytical process of objects contained in batches based on a repetitive distribution of longitudinal lines and transversal row on a conveyor that passes them in a line in longitudinal direction through a visiometric examination site that includes sensor means sensitive to emergent light beams retransmitted by the said objects, characterized in that the examination of each row is conducted in at least two stages or cycles of successive actions, illuminating the batches for examination by different doses of illumination and in a second stage illuminating only those batches that, in a preceding first stage, were not shown to present a condition that would cause, in a second stage, a glaring of the sensor means which could disturb the neighboring batches in the same row during the examination.
Considering the preferred fields of application of the invention, which present situations identical or similar to those of egg candling, that is, in which it is the intention to determine a condition to be attributed to each of the said objects on the basis of consequences they cause in a light beam to which they are exposed during the passage from each of the successive rows of a batch of eggs that are to be sorted on the basis of being clear or fertilized, or similar objects contained in cells of a crate grid forming said batches, there are certain secondary characteristics of the invention, which apply individually or simultaneously in any technically operative combination; these advantageous characteristics are as follows:
The two successive measurement cycles are advantageously conducted, respectively, in the course of a principal second stage carried out under conditions appropriate for determining a condition of transparency or similar condition affecting the decrease in the light beam in a noticeable manner for the sensor of the emergent beam, which is preceded by a first stage conducted under conditions appropriate for revealing the presence of empty cells and determining and recording the coordinates of their batches in the row being examined, in order to control the illumination conditions during the second stage to avoid illuminating them.
In addition, the radiation dose selected for the sensitivity range of each stage is advantageously regulated by varying the time of exposure at a determined emitting power. Because the radiation dose is selected for each stage to avoid risk of glare of the neighboring sensors around a batch without egg (or similar object), it can easily be seen that the duration of the objects' exposure, for each row, is relatively brief for the first stage and relatively long for the second stage.
The light source illuminating the objects to be examined is advantageously made up of a series of light-emitting diodes, or LED. These diodes or LED are arranged parallel to the rows of the batches to be analyzed, and thus in a direction perpendicular to the displacement of the objects moved by the conveyor. More precisely, they are aligned parallel to the rows of cells in the crate grid that receive the eggs, thus generally following a row perpendicular to the longitudinal direction of conveyance.
According to a secondary characteristic of the invention, the different illumination doses are applied during at least two successive cycles, sufficiently close together in time to illuminate the same row that is under way in the visiometric examination post, said cycles utilizing the same diode sources, at the same intensity, but for different durations, in order to accommodate at least two different ranges of sensitivity, while avoiding between one and the other the glare phenomenon in some or all of the photo detectors.
During the first measurement cycle, a relatively weak dose is applied and the automatic analysis apparatus detects the presence or absence of empty cells, and if any are found, it determines and stores their coordinates in the examined row (the ordinal number in the transversal position in this row). During the second measurement cycle, with a relatively strong dose the illumination of the only cell batches that are not empty are controlled. The automatic analysis apparatus discriminates, if they exist, those cells that contain clear eggs as opposed to those containing other categories of egg, particularly fertilized eggs, and it records the respective coordinates of these two potential categories of cells. These coordinates are particularly simple to express by the ordinal number of the cell in the row and the ordinal number of this row in the longitudinal line in the crate grid.
The luminous doses—respectively, relatively weak and relatively strong—are selected such that the second allows a contrast of the level of the photo detectors, to distinguish fertilized from non-fertilized eggs, and the first reveals the batches where the application of the second would involve for corresponding photo detectors the presence of too high a luminous intensity, which might cause a glare phenomenon.
Further characteristics of the invention concern the organization of spatial arrangements correlated to the photo detectors of the video camera and the diodes of illumination, where the activation of these two series of elements are synchronized by automatic control devices.
Thus, in the case where the cells present a quincunx configuration, it is advantageous to group the rows of cells two by two, providing a light source made up of a number of LED that is twice the number of cells per row. In this configuration, each diode is activated in correspondence with the passage in its field of one row of cells out of two. In other words, in this configuration, half of the diodes are associated with even-numbered lines of cells, and the other half with odd-numbered lines.
It is also possible to increase the number of illumination cycles, so that each cycle involves a different illumination dose (especially for a duration that is appropriate for a light intensity that remains identical), for instance, to use three cycles. During the third cycle, in the preferred application of the invention concerning egg candling, the automatic analysis apparatus distinguishes the eggs that are truly fertilized from other categories of non-clear eggs (eggs with false germ, rotten egg). Only the cells that can contain one or the other of these categories of non-clear eggs (following the analysis conducted during the second measurement cycle) are illuminated during the third cycle.
Following these successive discriminations, the eggs can be sorted and/or marked upon leaving the candling installation. In practice, and in a preferred embodiment, it is the clear eggs that are marked and/or sorted, and then eliminated, so that only fertilized eggs are preserved. In general, it is sufficient therefore to proceed in two stages, under working conditions determined so as not to illuminate empty cells during the second stage of illumination that allows detection of the presence of clear, non-fertilized eggs, considering that it is not important if among the correctly fertilized eggs there remain some eggs with false germ or even rotten eggs, neither of which could lead to the birth of a chick.
It can also be useful, however, to conduct a more thorough analysis by working in more than two stages. In particular, the invention makes it possible to draw up useful statistics by recording the results in computerized databases and submitting them to specially adapted computations to determine such data as the profitability of fertilization or the quality of a delivery received in a hatchery.
Concerning an apparatus, the invention particularly involves a system of optoelectronic analysis that applies preferably to an installation for candling eggs contained in crate grid cells that are adapted to showing at least two conditions, fertilized and clear respectively, such that said cells are arranged in batches based on a predetermined configuration of lines and rows.
Said installation includes, in a known manner, a conveyance apparatus that moves successive egg crate grids at a predetermined speed through a visiometric examination site that comprises a light source generating a light beam appropriate for each of said eggs in each successive row passing through said site, and means of synchronized detection of the emergent beams from said eggs, as well as means for automatically determining a condition of said eggs, particularly a fertilized or non-fertilized condition, on the basis of the attenuation caused by each egg in the corresponding beam.
In the various types of application of the invention that are best adapted to industrial practice, the light source is provided by a number of light-emitting diodes aligned parallel to the rows of batches receiving eggs in the crate grids (the cells), and the means of detection takes the form of a sensor made up of a chain of a number of photo-detectors sensitive to emitted light, the spatial configuration of which is correlated with that of said light-emitting diodes. Appropriate means are then foreseen to synchronously guide, first, the selective emission of beams by said light-emitting diodes in such a way as to simultaneously illuminate predetermined cells in each row passing through the examination site and, second, the reception of the emergent beams by photo-detectors of said sensor in spatial relation with the light-emitting diodes emitting light.
According to the invention such guidance is programmed to automatically ensure at least two measurement cycles of the decrease by light emission of predetermined duration delivering different doses of illuminations, each avoiding a glare of the detection means sensitive to emergent beams, namely a first cycle during which the emitted light illuminates all cells of the row under examination during the first duration, in order to determine the existence or non-existence of cells without an egg, taking the form of the detection of a non-attenuated light at high energy, and to register in the memory the coordinates of the batches according to whether the corresponding cells are void of an egg or not, and a second cycle during which the emitted light illuminates only the cells whose coordinates indicate that an egg is present, while a second duration, longer than said first duration, in order to discriminate fertilized eggs from clear eggs, by detection of different decreases in the light emerging from said eggs. For further exploitation, possibly in a later site of the same installation, means are provided for recording in memory the coordinates of fertilized and/or clear eggs.
The invention is now described in greater detail with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows schematically an example according to the invention of an installation for candling eggs incorporating a visiometric examination site as well as a marking site for non-fertilized eggs.
FIG. 2 shows schematically a preferred embodiment for a carton grid for transporting eggs to be examined, which are inserted into the installation of FIG. 1 , shown in partial overhead view.
FIG. 3 shows schematically a scale of luminous intensities of emergent beams for various categories of eggs when they are illuminated by an infrared light source.
FIG. 4 shows schematically a configuration of LED light source applied in the automatic detection and analysis system of FIG. 1 .
FIG. 5 shows a detail of an egg and the detection by a sensor of light retransmitted from said egg.
DETAILED DESCRIPTION OF THE INVENTION
Before describing, with reference to FIG. 1 , the functioning of the optoelectronic system that includes an automatic detection apparatus and an analysis apparatus for fertilized eggs in the strict sense, we describe here an example of the layout of an egg-candling installation 1 incorporating such a system, according to a preferred embodiment of the invention. In the figures that follow the common elements bear the same reference numbers and are re-described only as necessary.
With the exception of advantageous characteristics specific to the invention, which will be pointed out in detail below, the general layout of such an installation in for the most part basically common to those installations known in the art. Reference is made to the French patent 2 768 517, for instance. It is an additional advantage of the system of the invention that permits re-utilization of well-known technologies and of material that is financially amortized.
Thus the installation 1 comprises a conveyor 2 with rotating belt in closed circuit or equivalent apparatus, present in the illustrated example an entry area 20 and an exit area 21 . This conveyor displaces through the visiometric examination site, generally at fixed speed, carton grids containing eggs to be candled (not shown), which are introduced one at a time, manually, at the entry to the installation. The carton grids are advantageously the same that were used for incubating the eggs.
A visiometric examination site 3 is stationary between the two portions of the conveyor 20 and 21 . It comprises in the lower area a source of radiation 31 , which in the particular case considered here emits individual beams of infrared light, and in the upper area means of detection which are sensitive to the wavelength of the light emitted by the source 31 and are made up of discrete detectors or, preferably, of a video camera 30 . The source 31 as well as the sensor of the video camera 30 is described more completely hereafter, in terms of make-up and synchronized functioning, in relation to FIGS. 4 and 5 .
Each of the crate grids of eggs introduced successively on the conveyor 2 , for instance the crate grid 4 a , breaks the beam 310 emitted by the source 31 between the two portions of the conveyor. It comprises a number of cells in which eggs are placed for candling. The structure of these cells is such that they allow the passage of the beam 310 in the absence of eggs (the bottom is generally open). The eggs contained in these cells intercept the beam 310 and retransmit it with variable decrease according to their condition, and particularly, in the context of the application described here, as a function of their fertilized state, that is, whether the egg is fertilized or not. This effect that is to be measured is not due, strictly speaking, to the transparent quality of the egg, but rather to the degree of diffusion of the light that penetrates the egg. This, in addition, is why the measurement implies that the illumination beam strikes the corresponding shell of the egg, even if it does not exactly follow its axis.
The radiation registered by the video camera 30 is converted into electric signals that are transmitted onto an outlet connection 300 , advantageously in the form of numeric signals, first to a visualization element 9 , for instance a cathode screen (connection 301 ), and also to a data processing system with recorded program 6 (connection 302 ), referred to hereafter simply as a calculator. The latter can be a dedicated signal processor or can be of a standard type and equipped with appropriate ports. The calculator, using image processing, controlled by specific software in known manner in the art, analyzes the signals of images received from the video camera 30 . The image processing carried out in this manner makes it possible to determine whether the eggs analyzed are fertilized by situating the extent of attenuation in the light beam at the crossing of each egg in relation to threshold values that limit predetermined ranges.
In a variant embodiment of the described installation, the visualization element 9 , which is optional, can be controlled by signals received from the calculator 6 , and not directly from the video camera 30 , that is, after processing of the signals.
A preferred application for egg crate grids according to a practical embodiment of the invention, the crate grid 4 a for instance, is illustrated schematically in the detailed view in FIG. 2 (a partial overhead view). It shows a number of cells, referred to generally as 40 to 44 , that are intended to receive eggs for candling (not expressly shown). These cells 40 to 44 are arranged in successive rows aligned parallel with respect to one another and perpendicular to the longitudinal direction of motion (arrow f). The illustration thus depicts five rows R 0 to R 4 by four lines l 0 to l 3 in the longitudinal direction, in an arrangement based on an orthonormal matrix. However, from one row to the next, the cells are in a quincunx arrangement. In an arrangement that is more precisely hexagonal, they are offset by a half-step in the transversal direction between the even-numbered rows and the odd-numbered rows.
The infrared source 31 ( FIG. 1 ) is composed of a number of light-emitting diodes (LED). These diodes are arranged on a line parallel to the rows, R 0 to R 4 , of the crate grids, for instance 4 a ; that is, following an orthogonal direction to their movement. They are at a distance to one another, by the value of a half-step in the particular case considered here, so that each one passes through the successive cells of the same line respectively, in the course of the relative motion. LED 31 are controlled in pulse mode by the calculator 6 (connection 60 ) at a rhythm determined according to the speed of the conveyor, and synchronized with the procession of the cells, so that each diode produces a basic illuminating beam of one cell at the moment it passes in front of the diode, and thus that said beam is modified by the egg it contains before being detected by the video camera 30 in order to be analyzed.
FIG. 4 schematically illustrates the configuration of the light source 31 of FIG. 1 which is composed of a number of LED, emitting in the infrared range. These diodes are arranged in a line parallel to the rows of crate grids, and thus to a row R x of the x order assumed to be undergoing examination, that is following a perpendicular direction orthogonal to the longitudinal direction of procession through the visiometric examination site.
In the particular case illustrated for a configuration of cells in quincunx pattern, the number of diodes, D x1 to D x4 , is double that of the cells of one row. It is assumed that the row R x was of odd number and included cells 4×1 and 4×3 (assuming that there are four lines), symbolized by ellipses in dotted lines. The diodes have been labeled D x1 to D x4 . In the described example, at the moment depicted in FIG. 4 , only the diodes D x1 and D x3 are activated for the odd-numbered rows, because they are placed under the cells 4×1 and 4×3. When the following row of cells is above diodes, it is the diodes D x2 and D x4 that will be activated for this even-numbered row.
It is important, however, to emphasize that this arrangement is in no way restrictive for the conditions for applying the invention. Many situations exist in which it will instead be advantageous to produce the illumination by means of several groups of diodes, particularly two or three groups implanted beside one another. Thus the polyvalence of the machine is increased and it can easily be adapted to crate grids with different dimensions and steps. The illumination of the diodes is controlled selectively according to the arrangement of the cells in the crate grids. The selection of the diodes to be illuminated is functionally equivalent to the mechanical adjustment of the position of the diodes under the cells.
In all cases, each illuminated diode produces a basic beam intended to individually illuminate one of the cells of the row under examination in the visiometric site. The diodes as a whole are controlled in pulse mode by the calculator 6 : multiple connection 60 .
FIG. 5 schematically illustrates the illumination of an egg OX 1 , placed in cell 4×1 in the row R x by the diode D x1 .
The video camera 30 comprises a sensor labeled CCD as mentioned above. According to an important characteristic of the invention, the sensor CCD is controlled by the calculator 6 synchronously with the control of the diodes, D x1 to D x4 . In addition, the linear spatial configuration of this sensor is correlated with that of these diodes. The control of the sensor CCD is provided by the generation of command signals on a connection 62 linking the calculator to a command input of the video camera 30 .
Referring to the diagram of FIG. 3 , the illumination with precaution for a cell without eggs runs the risk of causing a glade of photo-detectors of the sensor CCD which receives the light flow that has not undergone any attenuation. The captured light intensity I 1 is in fact very high. To clarify, if the video camera being used tolerates an average current of 100 mA (after conversion of the luminous energy into electric signals), a luminous pulse causing a current of 1 A, if its duration is sufficient, will generate an average current exceeding the admitted limit of 100 mA. The glare phenomenon will thus be caused.
Thus, according to an important characteristic of the invention, it is likely that two measurement cycles will be applied to each row successively undergoing examination.
The first cycle consists in generating, under the command of the calculator (connection 60 ), a pulse of light illuminating each of all the cells in the row. The pulse command signals are transmitted to all diodes, D 11 to D 24 . Continuing by way of example, the duration of this pulse is typically on the order of 100 μs, for the video camera characteristics indicated above.
The first measurement cycle makes it possible to detect the possible batches of cells that contain no egg. The calculator 6 authorizes the activation (command signal on the connection 62 ) of the photo-detectors of sensor CCD situated on the lines of cells of the row under examination, receives (connection 302 ) the electric signals emitted from the optoelectronic conversion carried out by this sensor, analyzes the image signals thus received, and subjects them to an automatic processing after which it orders the recording, in memory elements (not shown) that are associated with it, coordinates in the current crate grid of empty cells whose existence was detected, contrary to the cells in which an egg is present.
Then a second measurement cycle is activated. Altogether or in part, the diodes D x1 to D x4 receive a second command pulse generated by the calculator 6 to illuminate once again the eggs present in their cells, for instance egg OX 1 . The illumination is selective. Only the diodes that correspond spatially with the non-empty cells are activated. On the connection 60 the calculator 6 therefore transmits command signals only to these diodes, on the basis of analytic results obtained at the end of the preceding cycle and of the recorded coordinates that distinguish the empty and non-empty cells. The pulse is of greater duration than that of the first pulse, so as to expose the eggs to a greater quantity of light, since use is made of identical light intensity. In synchronized manner, the calculator 6 sends a signal (connection 62 ) to the video camera authorizing the detection of the beams emitted by the activated diodes such as they are retransmitted attenuated by the eggs.
In another example, the duration of the pulse generated during the second cycle is typically of the order of 1 ms. This exposure time makes it possible to distinguish the clear eggs ( FIG. 3 : intensity I 2 ) from the other categories of eggs, the light intensities (I 3 to I 5 ) transmitted through eggs and received by the sensor CCD for these categories that are close to one another. This differentiation is effected by the calculator 6 , which to this end receives the signals (connection 302 ) emitted by the optoelectronic conversion performed by the sensor.
Since the empty cells (if they exist) are not exposed, there is no further risk of glare of the photo-detectors, because the attenuation caused by the other categories of eggs, whatever it may be, is sufficiently strong.
For each row in the process of testing the two cycles follow one another at a sufficient rapid rate so that the axes of vertical symmetry Delta ( FIG. 5 ) of the illuminated eggs do not have time to move significantly in terms of the test conditions, given the speed of motion that is imposed on them by the conveyor 2 ( FIG. 1 ) by relative transmission in terms of the emission equipment of the incident beams and the detection equipment of the emergent beams. This ensures that the beams emitted successively from one cycle to the other strike the same eggs correctly. This is illustrated in FIG. 5 , assuming that the beams pass through the egg OX 1 and leave in zones that are very close to one another, inside a clearly circular zone Zs of small radial dimension around the summit of the egg. This condition is easy to fulfill, because the speed of transmission of the conveyor is weak compared to the speeds that can be attained in the field of optoelectronics.
For further clarification, if we consider a rhythm of transport that is typically 36,000 eggs per hour, each row containing 6 eggs, and a step between cells of 40 mm (in a more general sense this step is assumed to be between 30 and 50 mm), the time passing under the video camera 30 is about a 600 ms. Considering the technology available for applications of this type, an estimated time of approximately 150 ms is easily sufficient to conduct the capture of images by the video camera 30 , and the analysis and processing of signals of images received by the calculator 6 . During this period, the egg summit will have advanced by only 10 mm, or +/−5 mm with respect to the axis. Double or triple this range is possible, while maintaining sufficient precision, since what matters is not that the beam passes through the egg following its diameter, but that it strikes the lower sphere of the shell. This explains the possibility of submitting each row of cells to a third measurement cycle, and possibly a fourth, while increasing each time the duration of exposure and excluding those batches that, in the previous stage, called the first stage, revealed for the corresponding egg a condition that would cause a glare of the sensor in the following stage (second stage).
In particular, this possibility can advantageously be exploited to obtain an additional discrimination between the categories of egg within the range G 3 ( FIG. 3 : rotten eggs, eggs truly fertilized, and eggs containing false germs). This is followed by a third measurement cycle, different in duration from the two preceding. As further clarification, the respective durations of the three cycles could typically be as follows: 100 μs, 1 ms, and 4 ms.
The course of the two first cycles is very close to what has just been described for a process with only two cycles. By the end of the two first cycles, a discrimination has been possible between the vacant cells (first cycle) and between, on the one hand, the clear eggs and, on the other hand, the other categories of eggs (second cycle). The coordinates of the categories of eggs that have thus been discriminated on the completion of the second cycle are recorded by the calculator 6 in the memory facility.
During the third cycle, the cells capable of containing eggs in the range G 3 ( FIG. 3 ) are illuminated by the third pulse. The mode of operation is similar to that of the second cycle. The calculator 6 puts out synchronized command signals to the video camera 30 and to the only diodes that are face to face with cells capable of containing eggs in a condition that leads to an attenuation of the range G 3 . Accordingly it becomes possible to distinguish these categories of eggs. An interesting application consists in separately listing each of the categories that have thus been distinguished, which forms a tool for evaluating the quality of the fertilization on the part of the incubator, of the degree to which the crate grids are filled, and of the yield that can be expected from the hatching device.
After analysis of the content of the crate grids and of the recording of the coordinates of the various categories discriminated, two at most, namely clear eggs and fertilized eggs (either bearing a false germ, or rotten), or a greater number of categories (process with three cycles or more), these crate grids continue their path into the interior of the candling installation, carried by the conveyor 2 until the exit from this installation 1 .
In practical terms, three principal possibilities exist (which can be cumulative):
candling eggs according to just one class or several classes; simple sorting; compilation of statistics recorded in computerized databases, displayed and/or printed on listings.
It is generally desirable to mark at least the clear eggs, non-fertilized, which are to be set aside from the line leading to the hatchery for the production of chicks. In practice, after marking they are manually eliminated on leaving the installation, and then possibly recovered. They can serve as food or as a culture medium for producing vaccines.
To mark the eggs selectively according to the category to which they belong, with their coordinates recorded in databases, although this information is not sufficient, the plan is to correlate temporally the emergence of an egg of a given category, which is meant to be marked, with the moment it is marked, which is done as the eggs pass, row by row, through a predetermined zone at the exit of this installation, past a marking apparatus. To accomplish this, with reference once again to FIG. 1 , there is a sensor 8 , of any appropriate type, that detects the beginning of the passage of a new crate grid of eggs to be candled on the conveyor 2 , for instance crate grid 4 b , and at a connection at the exit 80 provides a synchronous pulse transmitted to the calculator 6 . Preferably, in addition, the conveyor 2 comprises a displacement sensor 7 that, on a connection at the exit 70 , delivers signals that permit the determination of the amplitude of the motion of this conveyor 2 . These signals, correlated with the instant of emission of the synchronous pulse (connection 80 ), permit the calculation at any moment of the position reached by a given crate grid. In this manner it is possible, in particular, to know with precision the instant when a crate grid exits, for instance crate grid 4 a : labeled 4 ′ a when it leaves the installation 1 having run through the entire length of the portion of exit 21 of the conveyor 2 .
Specifically, in the particular application described to illustrate the operation of the invention, the marking system 5 according to the invention is essentially made up of a number of inking apparatuses with devices that emit ink, or jets. These apparatuses are installed immovably above the conveyor. Corresponding to the quincunx arrangement of the cells of the crate grid, they are distributed in two subassemblies 52 a and 52 b , also in quincunx pattern between two parallel rows having as many inking apparatuses as there are cells in a row of the crate grid. In the perpendicular direction, the distance between the inking apparatuses is equal to one step of the distribution of the cells, and this applies on each of the two rows. In the longitudinal direction the space between the two rows is advantageously equal to a half-step as for the cells, allowing to control all the inking apparatuses at the same time However, another procedure is also possible when, for instance, it is desirable to separate the two subassemblies farther from one another by using at the same time a selected processing speed slower in the marking site than in the optical examination site.
Each inking apparatus is made up identically of an oil injector like those used elsewhere in the automotive industry to feed fuel to the cylinders of an internal combustion engine. The injectors are fed by a pump 50 by way of conduits made up, for instance, of flexible tubing of synthetic material, connected to the same belt circuit 500 that is fed from a reservoir of coloring liquid 51 , by way of a conduit 510 in such a way as to maintain a constant liquid pressure in a buffer chamber for each injector. The coloring liquid is non-aqueous to avoid risks of rusting, and the various organs of the circuit, injectors and pumps, are constructed of steel alloys. A coloring product in an alcohol medium is preferably used. For a soluble coloring agent or an insoluble dispersed pigment, the alcohol has the dual advantage of being a readily available, economically priced organic solvent of being compatible with use in foods.
Control commands for the marking injectors are delivered by the calculator 6 in the form of pulses transmitted in two series of connections, 61 a and 61 b , and which, for each commanded marking injector, are addressed to an electromagnetic valve that determines the aperture of the jet releasing the coloring liquid, thus causing the emission of a pressurized spray of ink, 521 a or 521 b , that will mark the egg passing under the corresponding jet at this instant.
The marking system thus used according to the invention is particularly well adapted because the marks to be affixed on the eggs are simple ones, representing basic spots, and do not necessarily require preservation over time, and in addition the marking to be done does not concern all the objects passing through the installation but only some of them that have been identified in advance (particularly non-fertilized eggs). The requirements thus differ substantially from those prevailing, for instance, when eggs are to be marked for conveying precise information intended for consumers such as the laying date or similar details for which there is a need for sophisticated printing technologies to compose each character based on a matrix of pixels.
In terms of their mechanical installation, the inking apparatuses, with their respective jets, are immobile, advantageously fixed in place along the lines traversed by the objects on supporting rods perpendicular to the direction of motion, in an arrangement that aligns each of them with a corresponding object in the same row passing at their level. The inking liquid is permanently available there, under sufficient pressure so that the jet of ink reaches the object to be marked. For each individual jet, its release of ink is triggered by the opening of a valve at the moment when an object to be marked passes by. The absence of any contact between the inking apparatus itself and the object avoids the risk of any deterioration of the object so that in the case of eggs for instance, there is no danger of shell breakage.
In preferred embodiments of the marking system according to the invention, the inking apparatuses are installed on one or more rods forming supports that are arranged above the level traversed by the objects and aligned parallel to the rows of their distribution (perpendicular direction), so that the space between two injectors, or steps, is correlated to the step of the batches of objects, thus in particular to the step of the cells of the crate grids in the case of egg candling.
In a particular embodiment of the invention, the injectors of one rod are connected to their support by non-permanent hooking means allowing easy locking/unlocking and a regulation of the position of each injector along the support. Because of this characteristic, in which the injectors associated with a single row are installed on the support rod in positions that can be regulated laterally, the marking apparatus can easily accommodate various configurations of grids that contain the objects to be marked, whether eggs, fruits, or other items. Thus it is particularly easy to modify the distancing step between two adjacent injectors so that apparatuses can either maintain equal spacing among the batches in each row, or not.
In applications of the invention that are advantageous for situations where the crate grids have a quincunx arrangement of the cells, the marking apparatus, as described above, comprises two parallel supporting rods, so that the injectors of one rod are laterally unaligned with the injectors on the other rod in spatial correlation with the quincunx arrangement of the objects. In other embodiments of the invention that use variants, the injectors are mounted on their common support rod in such a way as to be able to move them laterally by a distance corresponding to the space between the objects from one row to the next and, on this basis, the lateral motion is controlled to correspond with the motion of the successive rows.
The marking command is given in coordination with the determination of the fertilized or non-fertilized condition of the eggs, depending on their lateral positions in a particular row of cells of the crate grid of on the time required for this row of cells to cover the distance separating their position during examination to determine their condition from their arrival in front of the printing jets that correspond to the cells receiving the eggs to be marked. In other words, in an installation that includes the marking system downstream from a candling system, the marking operations are performed at the same tempo as the visiometric examination operations, with a shift in time that is regulated by the speed of the conveyor that moves the egg crate grids along. | The invention relates to a system applicable to an installation for candling eggs, to determine the presence of fertilized eggs in the cells of the egg crate grid moving on a conveyor. Row by row, the analyzing device synchronously monitors the light emission on the eggs of the row and detection of the attenuated light of emerging beams. The monitoring includes at least two close cycles of light emission. During the first cycle, which is of short duration to avoid causing glare of the detectors of the detecting device, the coordinates of possible empty cells in a row are determined and stored. During the second cycle, which is of longer duration, the coordinates of fertilized eggs of the row are determined and stored. The egg candling installation advantageously also marks the eggs, depending in particular on whether they are fertilized or not. | 0 |
This application is a continuation, of application Ser. No. 673,377, filed 11-20-84 now aband.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a building block system.
2. Description of the Prior Art
Various shapes of building blocks have been proposed over many years for use in building vertical and horizontal walls. A relatively common proposal is of substantially T-shaped blocks, i.e. a block consisting solely of a stem limb and a cross limb, the stem limb extending substantially perpendicularly from the middle of the cross limb, examples being disclosed in British Patent Specification No. 590,291, French Patent Specifications Nos. 1067762 and 2299468 and U.S. Pat. No. Re. 14,904. In all of these cases, the block is laid such that the cross limb extends in the general plane of the wall, whilst the stem limb extends perpendicularly to that plane.
Swedish Patent Specification No. 150829 discloses a building block which, although it appears to be substantially T-shaped when seen in front elevation and rear elevation. The block actually consists of six limbs, of which four provide the front and rear T-shapes and of which each of the other two, links one end of the cross-limb of the front T-shape with the nearer end of the cross-limb of the rear T-shape. This building block has this special shape because it is used to form ventilation or like channels in the wall.
Although substantially T-shaped blocks, when interfitted with the free end of each stem limb face-to-face with the cross limbs of two adjacent blocks, utilize the interfitting to support each other at two opposite sides of the six sides of the block, they provide no similar support at any of the other four sides.
U.S. Pat. Ser. No. 829,480 discloses a paving and building block system wherein each block consists of two block-form parts whereof a larger part protrudes from the smaller part on four sides. These blocks can interfit such that the larger parts of four outer blocks overlap the larger part of an inner block at its respective four sides. Although forces applied to the major external face of the larger part of the inner block are borne by the larger parts of the four outer blocks, forces applied to the major external face of the smaller part of the inner block are not borne by any adjacent blocks.
In the above-mentioned U.S. Pat. No. Re. 14,904, each block has the end faces of its cross limb diverging towards its stem limb, and has the lateral faces of its stem limb substantially parallel to the respective nearer end faces of its cross limb and thus diverging away from the cross limb. Moreover, those two intermediate faces of the cross limb between these respective end faces, on the one hand, and these respective lateral faces, on the other hand, converge towards the longitudinal axis of the cross limb progressing inwardly. There is thus formed a keying arrangement of substantially Z-form which, in a wall constructed from the blocks, resists forces on those faces of any one of the blocks at the major faces of the wall. However, only one shape of block with such keying arrangement is provided, so that the system is of very limited use. Although the Specification discloses use of the blocks in a vertical wall, the blocks are arranged with their cross limbs vertical and their stem limbs horizontal. Thus, a bottom layer of special blocks has to be provided if the wall is to be laid on a planar foundation.
Federal German Patent Specification No. 1926239 discloses paving slabs each of which has at each of two opposite edge sides thereof a profile including a substantially Z-form key, the profiles on most of the slabs being identical to each other. The substantially Z-form keys of each slab are arranged to extend parallel to each other in the plane of the horizontal wall formed by the slabs. However, they are offset relative to each other along the respective opposite edge sides of the slab and are thus unsuitable for use in building a vertical wall with the substantially Z-form keys extending horizontally.
French Patent Specification No. 1352121 discloses a building system employing three shapes of interfittable elements, these shapes being substantially Z, substantially T and substantially L-shaped. However, forces against the free end face of the stem limb of such T-shaped element or against the free end face of the longer limb of such L-shaped element are not borne by the adjacent elements except by way of conventional fastening means, for example riveting, used to fix the elements together.
SUMMARY OF THE INVENTION
This invention seeks to provide a building system in which blocks are employed that are of compound shape, that is to say, are not basically rectangular parallelepipeds. The block employed in a system in accordance with the invention may be substantially T-shaped, substantially Z-shaped or may be dove-tailed and may co-operate with other compound-shaped blocks to produce buildings or other structures in which the various blocks strengthen and support one another with, or without, interlocking cooperation. It is possible for the buildings or other structures to be completed, in some cases, without mortar or other binding material between the blocks or, in other cases, to employ a relatively small amount of mortar or other binding material between the blocks as compared with buildings and other structures produced from conventional blocks, particularly bricks.
The present system advantageously employs blocks which are pre-fabricated to a high degree of precision and with which the required fitting together, especially interlocking, of the blocks will not be achieved, during the erection of a building or other structure, unless the individual blocks are correctly disposed relative to one another and register accurately. Thus, if a mistake is made in positioning a block relative to others that have already been laid, the error is almost immediately very obvious and can quickly and easily be corrected. No cutting or breaking of any block is necessary since the system advantageously includes the use of complementary blocks such as end blocks, corner blocks, or junction blocks. In the case of a building or other structure having upright walls, a minimum of checking is necessary upon the erection of those walls once the dimensions of the base of the building has been calculated and said base has been accurately marked out. An important feature of the system is the fact that the same block can by employed in the construction of floors and roofs as are used to erect vertical walls thus producing a fully integrated building system in which, once an initial choice of the various possible block shapes has been made, the number of different shapes of pre-fabricated block that are actually employed in a single building or other structure can be quite small.
According to one aspect of the present invention, there is provided a wall comprising a plurality of unitary building blocks each consisting of only two limbs which are a stem limb and a cross limb, the stem limb extending substantially perpendicularly from the middle of the cross limb, and the longitudinal axis of the cross limb extending in the general plane of the wall, wherein the improvement comprises the longitudinal axis of the stem limb also lying in said general plane.
Use of T-blocks in this manner in a wall, which may be a vertical wall, or a horizontal wall, for example a floor or a roof, gives a greater degree of flexibility in building construction, in particular with walls intended to bear no load or low loads, since these walls can be of lesser thickness than when the stem limbs of the blocks are perpendicular to the general plane.
According to another aspect of the present invention, there is provided a unitary building block comprising only two block-form parts whereof one part protrudes from the other part at first and second adjacent sides of said block to provide first and second keys thereat, wherein the improvement comprises said other part protruding from said one part at third and fourth adjacent sides of said block to provide third and fourth keys thereat.
This building block has the advantage that, when interfitted with identical building blocks in a wall, the blocks support each other not only against forces applied to two opposite sides of the block but also against forces applied to another two sides of the block.
According to a third aspect of the present invention, there is provided a range of building elements of various shapes, wherein the improvement is comprised in that the elements of various shapes are provided with substantially Z-form keys which are of substantially identical linear and angular dimensions to each other and each of which has its intermediate limb at an acute angle to its other two limbs.
This provision of substantially Z-keys on a range of variously shaped elements gives a greater degree of flexibility and strength in building construction.
According to a fourth aspect of the present invention, there is provided a substantially vertical wall comprising a plurality of unitary building blocks each formed at first and second opposite sides thereof with substantially Z-form keys. The keys of said blocks are substantially identical to each other and interfitting, and each block having at third and fourth opposite sides thereof alternating with said first and second opposite sides thereof respective substantially parallel faces. The improvement comprises said faces and the substantially Z-forms of the keys of the blocks extending in substantially horizontal planes.
A vertical wall constructed in this manner with blocks provided with Z-keys has the advantage that a lowermost course of the blocks can be laid directly on a horizontal foundation surface without requiring interposition of differently shaped blocks.
According to a fifth aspect of the present invention, there is provided a building block including at first and second opposite sides thereof respective first and second substantially Z-form keys whereof the substantially Z-forms extend in a substantially parallel manner to each other. The improvement comprises the first and second keys being situated directly opposite each other along said sides.
This block has the advantage that a plurality of them can be laid with their keys interfitting without requiring inversion of alternate blocks and without alternate blocks protruding significantly.
According to a sixth aspect of the present invention, there is provided a wall comprising a plurality of unitary building blocks each consisting of only two limbs which are a stem limb and a cross limb. The stem limb extends substantially perpendicularly from the middle of the cross limb, and the longitudinal axis of the cross limb extends in the general plane of the wall. The improvement comprises the longitudinal axes of the stem limbs of some of the blocks extending in said general plane and the longitudinal axes of the stem limbs of others of the blocks extending perpendicularly to said stem limbs of some of the blocks.
This arrangement of substantially T-shaped blocks is particularly useful in providing a relatively strong wall.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be clearly understood and readily carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
FIG. 1 shows a perspective view from above of a corner of two vertical walls of identical substantially T-shaped blocks of a building block system,
FIG. 2 shows a view similar to FIG. 1 of a modified arrangement of the substantially T-shaped blocks in the walls,
FIGS. 3A and 3B are a fragmentary elevation and a fragmentary plan view of a course of blocks in a wall of FIG. 1 or 2,
FIGS. 4A and 4B are a perspective view and a vertical sectional perspective view of one of the blocks of that course,
FIGS. 5A and 5B are views similar to FIGS. 3A and 3B of the course with a modified version of the block,
FIGS. 6A, 6B and 6C are a perspective view, a plan view and another perspective view of a second modified version of the substantially T-shaped block,
FIGS. 7A and 7B are a plan view and a perspective view of a corner substantially T-shaped block usable with the block of FIG. 6A,
FIGS. 8A and 8B are a perspective view and a plan view of two of those corner blocks interfitted,
FIG. 9 shows a perspective view from above of three walls built of the block of FIGS. 1 and 2,
FIGS. 10A and 10B shows a plan view and a perspective view of a modified version of the block of FIGS. 1 and 2 for use in the walls of FIG. 9,
FIG. 11 shows a view similar to FIG. 10B of a modified version of the block therein,
FIG. 12 shows a view similar to FIG. 10B of another modified version of the block therein,
FIG. 13 is a view similar to FIG. 10B of a further modified version of the block therein,
FIG. 14 is a view similar to FIG. 9 showing the walls built of a further modified version of the substantially T-shaped block,
FIG. 15 is a view similar to FIG. 9 showing the walls built of a variation of the block therein,
FIGS. 16A, 16B and 16C are a perspective view, a plan view and a side elevation of a substantially Z-shaped block of the system,
FIGS. 17A, 17B and 17C are end elevations of respective versions of a substantially Z-form key applicable to various of the blocks of the system,
FIG. 18 shows a perspective view of part of two interkeying courses of the block of FIG. 16A,
FIG. 19 shows an end elevation of the two courses of FIG. 18, but with a variation of the block of FIG. 16A,
FIG. 20 shows a modified version of the block of FIG. 16A,
FIG. 21 shows a fragmentary plan view of walls comprising the block of FIG. 16A,
FIG. 22A shows a perspective view of part of a course of another modified version of the block of FIG. 16A,
FIG. 22B shows a detail of FIG. 21, but modified,
FIGS. 23A and 23B show a perspective view and a plan view of a substantially dovetailed-T-shaped block of the system,
FIG. 24 shows a view similar to FIG. 21 of the walls comprising the block of FIG. 23A,
FIG. 25 shows a fragmentary perspective view of a horizontal wall, in this case a floor, comprised of the blocks of FIGS. 6A and 23A, and
FIG. 26 shows a fragmentary perspective view of a wall comprised of the block of FIGS. 1 and 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is made firstly to FIGS. 1 to 15 of the drawings which show the use of building blocks 1 that are substantially T-shaped. FIGS. 1 and 2 of the drawings show two upright walls 2 and 3 of a building or other structure formed from such T-shaped blocks. It will be seen that, in each horizontal course of blocks, neighboring blocks are alternately upright and inverted and that, in the structure of FIG. 1, each block is inverted relative to blocks which are vertically thereabove or therebeneath. In the structure shown in FIG. 2, each block in each course has the same disposition as does each block which is vertically thereabove or therebeneath. It will particularly be noted that, in both cases, the T-shaped blocks co-operate to form a 90° junction between the two upright walls without the need to employ blocks of any other shape. It will immediately be apparent that, measured in the general plane of its wall, the horizontal or cross limb 4 of each block is three units long, the vertical or stem limb 5 thereof is one unit long, and each limb 4 and 5 is one unit wide.
In fact, the basic T-shaped block of FIGS. 1 and 2 is preferably given tapered projections 6 to 8 and depressions 9 to 11 as shown in FIGS. 3 and 4 for a hollow block 12 and each one unit square in effective area, or projections 6' to 11' and depressions 6" to 11" each with an effective area of one unit by one-half unit, as shown in FIGS. 5. These projections and depressions provide significant keys between the blocks 12, enabling them to be fitted satisfactorily together without the use of mortar or other binding material when a wholly or principally dry construction is required. Moreover, the projections and depressions co-operate with each other to form satisfactory seals at the joints between the blocks which is a considerable advantage if the hollow blocks are to be filled with an initially foamed or liquid insulation material or with foamed or other concrete.
FIGS. 6, 7 and 8 of the drawings illustrate the form and use of blocks which may conveniently be described as Z-key, T-blocks. In FIGS. 6, the end faces of the cross limb 14 of the substantially T-shaped block 15 and the lateral faces of the stem limb 16 thereof are of a shape to give substantially Z-form keys 17. The keys 17 are identical to each other, especially in their linear and angular cross-sectional dimensions, with the intermediate limb 18 of each key being at an acute angle to its other two limbs 19. FIGS. 7 shows a corner substantially T-shaped block 20 which differs from the block 15 chiefly in that the key 17' of one branch of the cross limb 14 is arranged at a rear face of that cross limb. FIGS. 8 show two blocks 20 interfitted correspondingly to the blocks A and B in FIG. 1.
The substantially T-shaped blocks of FIGS. 6 to 8 are, in any construction employing them, keyed to their neighbors on two sides and this produces equilibrium among the forces acting on each block. It is noted that Z-keyed blocks are usable in slab form as floors and also in slab form as roofs which latter can be employed either with, or without, additional supports.
There are four basic versions of the embodiment of the system which principally uses substantially T-shaped building blocks. These four versions have been found to be the most satisfactory as regards ease of construction, handling, simplicity, ease of production of the blocks, versatility in use of the blocks and the need to produce a minimum number of accessory blocks for use at, for example, wall ends and wall junctions. The first of these four versions is illustrated in FIGS. 1 and 2, the second in FIGS. 9 to 13, the third in FIG. 26 and the fourth in Figure 15. It will be apparent that the versions shown in FIGS. 9 to 15 inclusive employ the substantially T-shaped blocks lying perpendicularly to the wall (i.e. with their cross limbs in the general plane of the wall and their stem limbs perpendicular to that plane.
Referring to FIG. 9, the vertical walls 30, 31 and 32 extending perpendicularly to each other consist of substantially T-shaped identical blocks 33 with cross limbs 34. The cross limbs 34 are three units long and one unit wide and stem limbs 35 one unit square. The substantially L-shaped identical blocks 36 have stem limbs 37 two units long and one unit wide and cross limbs 38 one unit square, and identical square-section blocks 39 one unit square. FIGS. 10 shows one of the blocks 33 with the end faces of its cross limb 34 and the lateral faces of its stem limb 35 consisting of substantially Z-form identical keys 17 which differ from the keys 17 of FIGS. 6 only in that their faces are perpendicular to the plane of the block. FIG. 11 shows a block 33 differing from that of FIGS. 10 only in that it has substantially Z-form keys 40 whereof the limbs of the substantially Z-shape are at right angles to each other. The block 33 of FIG. 12 is usable in walls according to both FIGS. 1 and 9 and has its keys 41 of substantially V-shape with the limbs of the substantially V-shape lying in a plane perpendicular to the axis of the stem limb 35. The block 33 of FIG. 13 differs from that of FIG. 12 only in that its keys 42 are of a cylindrical concave or cylindrical convex form.
FIG. 14 shows the walls 30 to 32 constructed of substantially T-shaped blocks 50, substantially L-shaped blocks 51 and substantially square-section blocks 52. FIG. 14 differs from the blocks of FIG. 9 chiefly in that the substantially T-shaped blocks each have one or both of those two faces 53 thereof intermediate the end faces of its cross limb, on the one hand, and the lateral faces of its stem limb, on the other hand, converging towards that face 54 of the cross limb opposite the stem limb.
In the version of FIG. 15, each substantially T-shaped block 50' is of elongate formation.
Each of the four versions of the embodiment of the system which principally employs substantially T-shaped blocks may be solid, or wholly or partly hollow, and may have plain and/or patterned or other textured faces. It will be apparent that many different combinations of precise shape, size, materials, surface texturing and so on are possible that are too numerous to discuss individually. The particular type which is chosen will depend upon individual preference, climatic conditions, geographic situation and local traditions of building. It is noted that, whilst prefabricated concrete will generally be employed and most blocks will be hollow in construction, other materials can equally well be used, if preferred, such as pre-stressed concrete to form blocks usable for vertical walls, floors, roofs and so on, but a construction employing concrete is not essential and the blocks can be made from, for example, glass-reinforced plastics, natural wood and/or plywood.
The use of the building system which has so far been described enables strong buildings or other structures to be made either in dry form or semi-dry form using considerably less mortar or other binding material than is employed in the formation of traditional brick/block buildings and the like. The described system has numerous advantages as compared with traditional building systems. These advantages include stability both during and after erection of a building or other structure, ease of erection, simplicity in aligning the blocks without long experience of such work being necessary, and the use of an absolute minimum of auxiliary tools, measuring instruments and other gadgets. The blocks can be such as to interkey, giving increased strength to the vertical wall, floor, roof or the like which is being produced simultaneously. The blocks will eliminate errors such as discrepancies in level and the formation of crooked, zig-zag, curved or other incorrectly disposed courses of blocks. The system is versatile since it can employ different forms of keying and can employ any chosen one, or any chosen suitable combination, of the different blocks that have already been described and those that will be described below. As well as being very suitable for the construction of dwelling houses and other buildings, the system can be used for many other purposes such as, for example, the paving of roads, pathways, pavements and the like and for the cladding of new or existing buildings. Although the blocks will usually be formed from conventional concrete, they can, as has already been mentioned above, be formed from other materials which include, in addition to the examples already mentioned, light-weight concrete, clay, gypsum and synthetic plastics whether or not reinforced with glass fibre or the like. Where appropriate, buildings or other structures can be produced without mortar or other binding material between the blocks but grouted cavities can be included, where required, for strength or insulation. If required, a building or other structure can be formed in such a way as to be capable of being readily dismantlable by including therein removable keying blocks or removable locking bolts. The blocks may be given surface textures designed to simulate the use of a traditional method of construction when viewing the exposed surfaces of a building or other structure formed from such blocks.
It has been found that, using principally the substantially T-shaped blocks to form a building or other structure, those blocks, when accurately produced, fit together in the manner shown in FIGS. 1 and 2 of the drawings in such a way as automatically to prevent inaccuracies in horizontal or vertical disposition, provided only that the foundation or footing is itself correctly disposed. The interengagement of the blocks automatically prevents vertical and horizontal inaccuracies from occurring. The fact that the blocks fit tightly together produces a strength which is comparable with that achieved by using traditional bricks or blocks that are connected to one another by mortar or other binding material. Considerable time is, of course, saved by wholly or principally omitting mortar or other binding materials since the builders do not have to wait for the mortar or the like to set before the blocks can be relied upon for supporting purposes. Although the blocks are pre-fabricated, a building or other structure which is to be formed principally therefrom is actually constructed in a very similar manner to the use of traditional bricks and blocks except that, generally speaking, mortar is used very sparingly, if at all. The final building or other structure will not have the appearance of a monolithic concrete mass but rather the appearance of a somewhat differently patterned, but otherwise traditional, block or brick construction, thus avoiding an unusual external appearance which tends to discourage builders and the customers for their products. Builders that work substantially only in the traditional way will find no difficulty nor strangeness in using this system since the system comprises placing a large number of relatively small blocks in pre-determined positions relative to one another as is, of course, done when using traditional bricks and building blocks.
As well as being employed in the construction of actual buildings, paths, roads and the like and the cladding of new or existing buildings, this system can be employed in producing either permanent or temporary shuttering, substantially T-shaped blocks which are formed from glass fibre reinforced plastics or wood being particularly suitable for shuttering purposes. If exceptional strength is required in the blocks, they may be formed from glass fibre reinforced concrete. However, the particular choice of material will naturally depend upon the nature of the building or other structure that is to be formed and the purpose for which it is required. The hollow interiors of the blocks can, for extra strength, be filled with concrete or cement grout and it is possible to insert reinforcing bars into those interiors, before pouring the concrete or grouting. It has already been mentioned that the hollow blocks can be filled with insulation material, such as urea-formaldehyde foam, by either pouring or injection.
The system is particularly convenient for forming temporary buildings or other structures since the blocks and other necessary items can be supplied in a partially assembled condition with post units bolted to beam units merely requiring the interlocking blocks to be correctly positioned. Under such circumstances it is, of course, necessary that provision should be made for disassembling the temporary building or other structure in one of the ways briefly discussed above.
It will be realized that the blocks that have been described can be provided in any required sizes although it is desirable that the size and weight should not exceed that which can readily be handled by a single workman. The blocks that have briefly been described with reference to FIG. 15 can, on the other hand, be of such a size that mechanical assistance is required to move them. It is possible to provide blocks other than those shown in FIG. 15 to form a range of modular units that are basically of T-shaped cross-section together with accessory units as may be required at wall ends, wall junctions, the margins of access openings and the like. The second and third versions of the substantially T-shaped blocks may, if required, be of brick-sized dimensions and may be made from baked clay and other materials from which conventional bricks are formed. In a building or other structure using such bricks, it is desirable to grout the junctions between them at regular intervals, as may be necessary having regard to the particular building or other structure that is being produced. In the case of hollow blocks of this form, the block may be filled with mortar to produce columns or pillars and to strengthen the construction at the junctions between walls.
When erecting a building or other structure using the first version of the blocks that has been described with reference to FIGS. 1 and 2 of the drawings, it will be remembered that these blocks do not possess any interkeying features and it is therefore desirable, although not absolutely essential in all cases, to use mortar, grouting or other binding material in each pair or tier of blocks, using further mortar, grouting or other binding material between superposed pairs or tiers of blocks. The blocks that are required at the corners and ends of walls are basically similar to the substantially T-shaped blocks themselves, except the form of keying matches that employed in the substantially T-shaped blocks.
In employing the third version shown in FIG. 26 to form a building or other structure, much the same technique is used as with the first version but the relative disposition of the blocks is different. The substantially T-shaped blocks 60 with cross limbs 61 and stem limbs 62 in the general plane of the wall interfitting with substantially T-shaped blocks 63 with cross limbs 64 and stem limbs 65 perpendicular to the limbs 61 and 62, respectively. The thicknesses of the substantially T-shaped blocks employed can be varied, and in particular reduced, to allow different external patterns to be produced together with different relative dispositions of the blocks. This third version can, if desired, be combined with the second version, using the two versions alternately in successive tiers of the blocks.
A second basic embodiment of this building system employs blocks that are not T-shaped but that co-operate with one another by way of keys that are still substantially Z-shaped. Such blocks are particularly, but not exclusively, useful in forming prefabricated panels, partitions and the like. A minimum of mortar or other binding material is required at the junctions between the blocks.
The substantially Z-shape of the key can be varied but it has been found convenient to employ four basic forms of the key any of which will join the blocks quickly and effectively together without essentially employing any mortar or other binding material.
It is possible to build a wall or other structure employing substantially Z-keyed blocks in a semi-dry form, overlaying every tier of the blocks with mortar or other binding material to secure the superposed tiers together in a conventional way. If a fully dry construction is preferred, it is desirable to incorporate end keying systems of substantially V-form, substantially arcuate, or substantially Z-form into the blocks to ensure that a building or other structure can be erected quickly and accurately whilst automatically maintaining stability and both vertical and horizontal alignment.
FIG. 16 shows a substantially Z-shaped block 70 consisting of two block-form parts 71 of which one part protrudes beyond the other on two of the six sides thereof and of which the other part protrudes beyond the one part on another two of the six sides. As a result of such protrusion, substantially four Z-shaped keys 72 to 75 are formed at the four sides, the substantially Z-shapes of the two opposite keys 72 and 74 being parallel and identical and of an acute-angled form, whilst the substantially Z-shapes of the two opposite keys 73 and 75 are of a right-angled form although parallel and identical to each other. As can be seen from the grids in FIGS. 16A and 16C, each block 70 is four units high, and each part 71 being two units high. The top and bottom faces of the block are each four units square; the intermediate limbs of the substantially Z-shape of the keys 72 and 74 are each two units long; the mid-point of the substantially Z-shape of each of the keys 72 and 74 is in a straight line with the free ends of that shape; and the intermediate limb of the substantially Z-shape of each of the keys 73 and 75 is one-third unit long.
FIGS. 17A, 17B and 17C show three different forms of acute-angled, substantially Z-shaped key. The key of FIG. 17A is that of FIGS. 6, 7, 8, 10 and 16. Figure 17B shows a key whereof the intermediate limb 80 is one unit long and the other two limbs 81 each extend, as measured in a direction parallel to the limb 80, one unit. In FIG. 17C, the key is similar in proportions to the key of FIG. 17A, but extends over only two units of the four-unit height of the block.
FIG. 18 shows two courses of the blocks 70, illustrating that not only do the blocks interkey in each course by means of the keys 72 and 74 but the blocks interkey between courses by means of the keys 73 and 75.
FIG. 19 shows that the keys 73 and 75 may also be of an acute-angled, substantially Z-shape.
FIG. 20 illustrates a substantially Z-shaped block 90 with acute-angled substantially Z-shaped, parallel, identical keys 91 and 92, the intermediate limb 93 of each substantially Z-shape extending obliquely inwards.
FIG. 21 is a plan view showing vertical walls 100 to 102 of a building that are formed by employing hollow blocks exhibiting the key of FIG. 17A, but FIG. 21 also shows the shapes of blocks that are required at a right-angled junction between two walls, two forms of T-junction between walls, and a cruciform junction between four walls,
FIG. 22A illustrates hollow, substantially Z-form keyed, substantially Z-shaped blocks 110 which are used as permanent formwork for the construction of beams together with details of one way of fitting those blocks 110 together. FIG. 22B shows the shape of auxiliary hollow blocks 120, 120' that may be used surroundingly to support upright reinforcing rods or the like that are interconnected by strengthening wires.
The substantially Z-shaped blocks that have been described herein can be employed in much the same situations as the substantially T-shaped blocks discussed above and, to a large extent, have the same advantages, as compared with the blocks that are employed in conventional building systems, as do those above-discussed blocks.
There now follows with reference to FIG. 23 a description of a third basic embodiment of blocks employable in a building system which blocks 130 are of dove-tailed substantially T-shape and will hereinafter be called, for the sake of brevity, "dove" blocks. Such blocks are again particularly, but by no means exclusively, useful in constructing pre-fabricated panels, partitions and the like, very little, if any, mortar or other binding material being required at the junctions between the blocks. The dove blocks again employ substantially Z-form keys for interengagement and, once again, these keys may be of various shapes but conveniently are provided in four different versions as has already been described above with reference to FIGS. 17 to 20.
Again, as already briefly described with reference to FIGS. 16 to 22, the dove blocks can advantageously be used in buildings or other structures of semi-dry form, each tier of dove blocks being overlaid with mortar or other binding material to secure it to the superposed tier in a substantially conventional manner. Again, if a substantially fully dry construction is required, it is preferable for the dove blocks to incorporate end keys of one of the same forms, and for the same purposes, as have already been mentioned with reference to FIGS. 16 to 19.
Each dove block is actually shaped to comprise two substantially Z-shaped keys 131 each extending over the whole of one side of the block. This form of block has the particular advantage that, in use, the forces acting on the opposite ends thereof will almost always substantially counterbalance one another so that a particularly structurally stable building will result.
The dove blocks 130 have substantially the same versatility of usage, and advantages as compared with the bricks or blocks that are employed in conventional building systems, that have already been discussed above in regard to the version of the system which principally employs substantially T-shaped blocks.
FIG. 24 is a plan view, somewhat similar to FIG. 21, showing a plurality of the hollow dove blocks 130 employed in vertical walls 100 to 102 which also include matchingly shaped cruciform connecting blocks 132, "half" wall end blocks 133, T-junction blocks 134 and right-angled corner blocks 135.
A description will now be given of ways in which the various forms of block that have so far been described can be employed in forming buildings and other structures. When substantially T-shaped or other blocks of the kind that have been described, having substantially Z-form keys, are used in co-operation with one another, the keys will effectively lock adjoining blocks together by directing the forces which act upon the junctions between the blocks and otherwise upon the blocks themselves in such a way as to enhance or reinforce the stability of the structure that is composed of said blocks. In particular, the keys transform the tensile forces to which the described blocks are subject into compressive forces which latter forces will not normally crush building materials of the kind used to produce blocks, unless these forces are excessively strong.
FIG. 25 illustrates one form of floor that may be constructed of substantially T-shaped blocks arranged with their stem limbs horizontal in a pre-cast concrete or steel beam or timber joist framework 140 that is of matching cross-sectional shape and that provides beams or joists at pre-determined substantially regular intervals. It will be noted that the substantially T-shaped blocks exhibit substantially Z-form keys of the kind shown in FIG. 20 and that similarly keyed dove blocks are also employed to fill the gaps which would be left if the substantially T-shaped blocks alone were used.
It is important, when using the blocks in the way that is illustrated in FIG. 25 that the blocks should be forced tightly against one another in a horizontal direction that is perpendicular to the lengths of the beams or joists of the co-operating framework. Under such circumstances, the blocks will co-operate effectively with one another to form a stable floor in which no underneath support, between the beams or joists, is necessary. A tie beam may often advantageously be employed to maintain the blocks firmly pressed against one another as just described, such tie beam being either pre-cast or cast in situ. The use of a tie beam for this purpose is particularly advantageous when the blocks are in the form of roof slabs. Obviously, there is a limit to the span of blocks which will remain reliably interconnected, without support, merely by the co-operation of their own interkeying portions, this limit being dependent upon the sizes of the blocks that are employed, the strength of the material from which they are made and the load that, in use, they will be called upon to bear. It is again possible to employ pre-cast or pre-stressed beams in supporting co-operation with the blocks, the blocks of a floor or the like that is formed in this way needing no mortar, grouting or other binding material.
If necessary, further strengthening can be produced by forming substantially Z-shaped keys on those surfaces of the floor blocks that are substantially perpendicular to the surfaces carrying the keys that have already been mentioned.
It can sometimes be an advantage to secure pre-cast or pre-stressed beams together to form a block in the form of a frame. This has the advantage that the beams will be lighter in weight than is conventional, thus avoiding the need for heavy lifting machinery and other mechanical handling equipment to move various parts of the building or other structure that is being erected into their appointed positions. Once again, if the beams are provided with substantially Z-form keying as described above, the advantage that the blocks automatically position themselves relative to one another in both vertical and horizontal directions is immediately attained. Also, since no mortar or other binding material is really necessary between the automatically interlocking blocks, a roof can be placed on a building or other structure erected using this system without having to wait for mortar or other binding material to set and attain a required degree of strength. | A building system for the construction of walls, floors, roofs, paths and roads employs prefabricated blocks having compound shapes which are such that at least a majority thereof each exhibit projections or recesses arranged to co-operate interkeyingly with the projections or rcesses of other blocks of the system, whereby the blocks can be assembled without the essential use of mortar or other intervening binding material. The blocks may be substantially T- or Z-shaped, having a hollow formation and being flat-laid, or disposed upright, in horizontal courses in vertical walls. The hollow interiors of the blocks may be filled with strengthening material or heat-and sound-insulating material or reinforcing bars may extend through aligned hollow interiors in the superposed courses. Compound-shaped corner and junction blocks are employed, where required. | 4 |
FIELD OF THE INVENTION
This invention relates to apparatus and methods for sealing film used to wrap products. The invention more specifically relates to the construction of sealing bars and to methods for the heat-sealing of film as used in the practice of packaging products such as poultry and the like.
BACKGROUND OF THE INVENTION
U.S. Pat. Nos. 4,907,399, and 5,329,745, the teachings of which are incorporated by reference, illustrate typical packaging machines in which the packages produced consist of trays filled with poultry or other products which are wrapped with a polymeric film capable of being heat sealed. A particular film capable of being heat sealed is referred to as a shrink-wrap film. In a typical method of wrapping packages of this kind, each tray with its products is enclosed in a tube formed of film whose longitudinal edges are first sealed to each other parallel to the axis of the tube so as to produce what is called a longitudinal seal. In a succeeding stage of wrapping, the film tube is both sealed and parted along a selected line at the leading and trailing end of the tray to produce what are called the transverse end seals. U.S. Pat. Nos. 5,063,327 and 5,421,139 illustrate such longitudinal and end seals, the teachings of which are also incorporated by reference.
Longitudinal seals are typically formed by feeding the longitudinal opposed edges of the film between a pair of heated rollers as illustrated in U.S. Pat. No. 5,329,745. In this regard, it has been observed that when longitudinal seals are formed in this manner with film and particularly with shrink-wrap film, the longitudinal seals are generally found to be reliable. It has also been observed that when longitudinal seals are formed by pressing the edges of film between heated rollers, a different kind of sealing action takes place than when end seals are formed by engaging the surfaces of two sealing bars as taught in U.S. Pat. No. 5,3292,745. The end seals produced are typically not as reliable as the longitudinal seals. This difference in seal strength is particularly true in the case of shrink-wrap film when the end seals are formed by means of conventional sealing bars.
While not thoroughly understood, it is believed that the relatively poor quality of end seals is due to the fact each end seal incorporates an end of a previously formed longitudinal seal. The invention recognizes that a factor contributing to the relatively poor quality of end seals may reside in the differences in physical contact which occurs when pulling edges of film through heated rollers as compared to pressing the film between two heated bars.
Thus, the object of the invention becomes that of providing an improved apparatus and method for forming seals with film and particularly with regard to forming end seals with shrink-wrap film. Other objects will become apparent as the description proceeds.
SUMMARY OF THE INVENTION
The invention resides in a method and apparatus intended to provide a heat-sealing mechanism primarily for shrink film but applicable to any type of heat-sealable film in which two surfaces come into engagement along a selected line under pressure and in the presence of heat. During at least a major portion of the sealing process one sealing bar is made to move relative to the other sealing bar in a direction parallel to the line along which the seal is formed and under appropriate compression according to the material being sealed. The relative movement is caused to occur from the time of first contact until at least the time at which the seal is completed and the film is severed between succeeding packages.
DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic side view of a set of disengaged sealing bars according to the invention.
FIG. 2 is a side view of the sealing bars of FIG. 1 when engagement has just occurred.
FIG. 3 is a side view of the sealing bars of FIG. 2 when engagement is full and the upper sealing bar has shifted laterally across the lower sealing bar.
FIG. 4 is an end view of the FIG. 1 sealing bars taken in the direction of line 1--1 of FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 illustrates a modified sealing mechanism according to the invention, having an upper sealing bar assembly 10, a lower sealing bar 12, an upper cylinder 14 for applying downward force (as per arrow x) to upper sealing bar 10 and a lower cylinder 16 for applying upward force (as per arrow y) to lower sealing bar 12. Upper sealing bar 10 comprises a support bar 20, a sealing bar 22, a set of connecting links 24 and a helical spring 26. Spring 26 is mounted so as to assert a longitudinal tension to sealing bar 22 with respect to support bar 20.
As illustrated in FIG. 1, sealing bar 22 resides in its resting position, below and somewhat to the left of support bar 20, by means of connecting links 24, pivotally connected to respective sealing bar 22 and support bar 24 with pins 28, or the like. Connecting links 24 are held under tension of spring 26 at a slight angle K to the vertical. At stop, such as pin 32 is secured adjacent one or more of links 24 to define the link position at angle K. When sealing bar 22 is caused to be raised toward support bar 20, connecting links 24 cause sealing bar 22 to shift simultaneously to the right, as shown. While illustrated in the preferred embodiment employing connecting links, the principles of the invention may also be practiced with other mechanisms, such as, for example, cams.
In operation, sealing bar assembly 10 and lower sealing bar 12 are kept separated by a selected height H during a time in the packaging cycle when a package P (see FIG. 4) is moved from an upstream to a downstream position relative to the sealing station (see arrow Z). Height H is set to be sufficient to allow a package P to pass freely between sealing bar assembly 10 and lower sealing bar 12 to position sequential portions of film F for sealing (see FIG. 4). After package P has passed between sealing bar assembly 10 and lower sealing bar 12 both upper cylinder 14 and lower cylinder 16 are simultaneously activated, bringing the sealing mechanism into contact with film F to be sealed. As seen in FIG. 2, sealing bar 20 initially contacts lower sealing bar 12 with connecting links 24 at the same angle K to the vertical as seen in FIG. 1. At this point, the upper and lower portions of film (now shown in FIGS. 1 or 2) that are to be heat sealed together along a selected line are in contact under minimal pressure. In some embodiments of the invention, the sealing mechanism disclosed herein is transported cyclically in a direction of travel parallel to arrow D in a manner that the opposed sealing bars 20, 12 are in contact with one another when travelling in the direction of arrow D and separated when travelling in an opposite direction.
Continuing with FIGS. 2 and 3, upper cylinder 14 and lower cylinder 16 continue to apply force to the respective sealing bar assembly 10 and lower sealing bar 12, causing connecting links 24 to rotate further from vertical and sealing bar 22 move to the right (as per arrow Z). When in full engagement with each other, sealing bar 22 is substantially laterally aligned with lower sealing bar 12 as illustrated in FIG. 3. A preferred embodiment of the invention results in a lateral movement of sealing bar 20 of approximately 1 cm (3/8 inch). The relative lateral movement (in the direction of arrow Z) of sealing bar 22, while pressing against lower sealing bar 12 causes a kneading action to the seam area being heated, thus improving the integrity of the resultant seam. Throughout the closure motion of the sealing apparatus described, helical spring 26 is being extended, causing a biasing of sealing bar 22. Alternate methods of biasing sealing bar 22 may satisfactorily be employed.
Upon the completion of the seal time, cylinders 14, 16 are reversed and cause upper sealing bar assembly 10 and lower sealing bar 12 to separate. Since heat is applied to the film being sealed through the sealing bars, a degree of sealing continues to occur during the reverse motion of raising sealing bar assembly 10 and lowering lower sealing bar 12. As the sealing apparatus is disengaged, spring 26 assists in returning sealing bar 20 to its position as in FIG. 1.
As seen best in the side elevation view of FIG. 4, sealing bar assembly 10 and lower sealing bar 12 are illustrated in an intermediate position about to contact the upper and lower portions of the film tube formed of film F for sealing. Successive packages P are transported from an upstream to a downstream position (as per arrow D) by conveyors C. A parting blade 36 is positioned between a pair of film grips 34 on the lower surface of sealing bar 22. Parting blade 36 may be in the form of a bar of triangular cross section with its apex directed downward toward lower sealing bar 12. Parting blade 36 is heated electrically by power through connecting cord 34, according to the preferred embodiment, and is formed to both create a seal between the upper and lower portions of film F and to part film F between successive packages P. A resilient strip 38 is secured on the upper surface of lower sealing bar 12 to act as a cushion against which sealing blade 36 is pressed. Lower sealing bar 12 and resilient strip 38 may but typically are not heated in the preferred embodiment. With certain types of film F, a heated lower sealing bar may be beneficial. Resilient strip 38 is made of a thermally tolerant resilient material, such as, for example, silicone rubber; different density rubber material or cross sectional shape (e.g. hollow extruded shape) may be employed depending on the particular film polymer and gauge being sealed. A heat protective surface sheet, such as fiberglass reinforced teflon (not shown), may also be superimposed on resilient strip 38.
It has been found that with the lateral kneading action achieved by the apparatus of the invention, a superior seam is formed with parting blade 36 and film grips 34 at a substantially reduced temperature compared to what was previously required. In addition to a lower operating temperature, the method disclosed improves the quality of the heat-assisted parting cut between packages and appears to eliminate previously observed bubbles in the sealing area, adding to the seam integrity and appearance.
While not shown, it should be understood that the invention lends itself to rotary type sealing bars and also to the type of sealing bars in which one bar is held stationary and the other bar is moved by a pneumatic cylinder or the like. Furthermore, the present invention is useful rotated 90° from the orientation of the example shown herein, such as would be applied to sealing packages in what is known as a vertical form fill operation. Also to be understood is the fact that the sealing operation can be accomplished at one station by the method and apparatus of the invention and the parting operation at another station.
Since the preferred embodiment disclosed involves only one of a variety of the embodiments possible within the spirit and scope of the invention, such variations to achieve the objects and advantages of the invention are considered to be a part of the invention contained herein. | A method of apparatus for heat sealing two portions of film associated with packaging of a product is based on bringing the two portions of film being joined together under pressure of mating sealing components, heating the juncture between the portions and during the time such pressure and heat is being applied, forcing one of the sealing components engaging the film to shift relative to the other of the sealing components in the direction of the seal whereby to improve the quality of the seal. | 1 |
RELATED APPLICATIONS
The present application is based on, and claims priority from, Taiwan Application Serial Number 95108212, filed Mar. 10, 2006, the disclosure of which is hereby incorporated by reference herein in its entirety.
BACKGROUND
1. Field of the Invention
The present invention relates to a power tool machine. More particularly, the present invention relates to a power tool machine with a holding apparatus for securing a workpiece in position on the power tool machine.
2. Description of Related Art
With reference to FIG. 1 , a power tool machine 100 such as a miter saw in accordance with prior art includes a base 110 , a fence 120 , a cutting arm 130 , a motor 140 , a saw blade 150 , a holding apparatus 160 and a setscrew 1621 . The base 110 provides an operating surface 111 on which the fence 120 is mounted. The fence 120 provides a standing surface 121 that is perpendicular to the operating surface 111 . A workpiece put on the operating surface 111 can be abutted against the standing surface 121 for accurate and precise cuts.
The cutting arm 130 is pivotally mounted to the base 110 and holds the saw blade 150 and the motor 140 . The saw blade 150 rotated by the motor 140 cuts the workpiece put on the base and abutted against the fence 120 when the cutting arm 130 is pivoted toward the base 110 .
With further reference to FIG. 2 , the holding apparatus 160 in accordance with the prior art is used to fix the workpiece in position for being cut. The holding apparatus 160 is generally mounted on the base 110 for pressing the workpiece and includes a post 161 , a transverse arm 162 , a threaded rod 163 and a pressing disk 164 . The post 161 stands on the base 100 and provides a plane 1611 at its upper portion. The upper portion of the post 161 passes through the transverse arm 162 . The setscrew 1621 is screwed into the transverse arm 162 to press the plane 1611 to make the transverse arm 162 fastened.
The threaded rod 163 is screwed through the transverse arm 162 and perpendicular to transverse arm 162 . The pressing disk 164 is attached to the lowest end of the threaded rod 163 to press and hold the workpiece 170 in position by rotating the threaded rod 163 . Therefore, the miter saw 100 can accurately cut the workpiece 170 with the aid of the holding apparatus 160 .
However, since the threaded rod 163 is not adjustable to substantially perpendicular to the operating surface 111 of the base 110 , the holding apparatus 160 can be only used to press the workpiece with a top side substantially perpendicular to the standing surface 121 of the fence 120 . If the top side of the workpiece is tilting, the holding apparatus 160 will become useless.
SUMMARY
An object of the present invention is to provide a holding apparatus for a power tool machine. The holding apparatus can press a workpiece with a horizontal or inclined top side when the workpiece is put on the power tool machine.
The power tool machine includes a base, a fence, a cutting arm, a motor, a saw blade and a holding apparatus. The base provides an operating surface on which the workpiece is put. The fence, which provides a standing surface substantially perpendicular to the operating surface for retaining one side of the workpiece, is mounted on the operating surface. The cutting arm is pivotally connected to the base. The motor is mounted to the cutting arm. The saw blade is mounted to the cutting arm and rotated by the motor to work at the workpiece.
The holding apparatus includes a supporting device, a connecting device, an adjustable device and a pressing device. The supporting device stands on the base and links up a body of the connecting device. The body of the connecting device is arranged substantially horizontal to the operating surface. The adjustable device is pivotally coupled to the connecting device. The pressing device is connected to the adjustable device for selectively pressing another side of the workpiece.
Since the connecting device is arranged substantially horizontal to the operating surface, and the adjustable device, relative to the connecting device, could be rotated, in the present invention the adjustable device could be moved to form an angle with or to be parallel with the connecting device. That makes the angle between the length direction of the pressing device and the operating surface changeable, so that the pressing device can press a workpiece with a horizontal or an inclined top. In addition, a positioning device is disposed to the connecting device and the adjustable device to make the user quickly, easily adjust the angle between the connecting device and the adjustable device.
BRIEF DESCRIPTION OF THE DRAWINGS
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 where:
FIG. 1 is a perspective view of a power tool machine with a holding apparatus in accordance with prior art;
FIG. 2 is an enlarged operational, sectional view of the holding apparatus in FIG. 1 ;
FIG. 3 is a perspective view of a power tool machine with a holding apparatus in accordance with present invention;
FIG. 4 is an exploded, perspective view of the holding apparatus in FIG. 3 ;
FIG. 5 is a perspective view of the holding apparatus in FIG. 3 ;
FIG. 6 is a perspective view of alternative embodiments of a supporting device of the holding apparatus in FIG. 4 ;
FIG. 7 is an enlarged, operational and sectional view of the holding apparatus in accordance with the present invention;
FIG. 8 is an enlarged, operational view of the holding apparatus in FIG. 7 when an adjustable device of the holding apparatus is slidably and pivotally adjusted; and
FIG. 9 is an enlarged, operational and sectional view of the holding apparatus in accordance with the present invention when the holding apparatus presses a workpiece with a triangular profile.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
With reference to FIG. 3 , a power tool machine 200 such as a miter saw in accordance with the present invention includes a base 210 , a fence 220 , a cutting arm 230 , a motor 240 , a saw blade 250 and a holding apparatus 260 .
The base 210 provides an operating surface 211 or supporting a workpiece, and is generally categorized into two types, with turntable type and without turntable type. The base 210 shown in the FIG. 3 is a turntable type. The fence 220 is mounted on the base 210 and provides a standing surface 221 that is substantially perpendicular to the operating surface 211 . A workpiece can be abutted against the standing surface 221 for accurate and precise cuts. An end portion of the cutting arm 230 is pivotally mounted to the base 210 , and the other end portion holds the saw blade 250 and the motor 240 . The motor 240 rotates the saw blade 250 to cut the workpiece abutted against the fence 220 when the cutting arm 230 is pivoted toward the base 210 . The holding apparatus 260 is mounted to the base 210 and cooperates with the surfaces 211 and 221 to firmly secure the workpiece in position.
With reference to FIGS. 4 and 5 , the holding apparatus 260 includes a supporting device 261 , a connecting device 262 , an adjustable device 263 and a pressing device 264 .
The supporting device 261 is rod-shaped, inserted into the base 210 , and provides a flat surface 2611 at its upper part.
The connecting device 262 is slidably mounted on the supporting device 261 and includes a body 2621 , a bolt 2622 , two first locking pins 2623 , two second locking pins 2624 and a fixing member 2625 . The body 2621 has a first end portion 2627 , a second end portion 2628 , a through hole 26211 , a threaded hole 2626 and a guide pin hole 26212 . The through hole 26211 passes through the second end portion 2628 of the body 2621 . The supporting device 261 passes through the through hole 26211 . The threaded hole 2626 is defined at the second end portion 2628 , communicates with the through hole 26211 and is generally perpendicular to the through hole 26211 in their axial directions. The fixing member 2625 has a threaded shank that is screwed into the threaded hole 2626 to abut the flat surface 2611 for fastening the connecting device 262 on the supporting device 261 and preventing the connecting device 262 from swinging about the supporting device 261 . To release the fixing member 2625 can make the connecting device 262 movable along the supporting device 261 so that user can adjust the height of the connecting device 262 up the operating surface 211 . The first locking pins 2623 are mounted respectively, symmetrically on the sides of the first end portion 2627 of the body 2621 , as two protrusions. The second locking pins 2624 are mounted respectively, symmetrically on the sides of the second end portion 2628 of the body 2621 , as two protrusions. The guide pin hole 26212 is defined at the first end portion 2627 .
With further reference to FIG. 6 , in alternative embodiments, substitutions of the flat surface 2611 of the supporting device 261 are implemented with a slot 2612 or multiple positioning holes 2613 . The positioning holes 2613 can be through holes or blind holes and are arranged equidistantly. Therefore, it positions the connecting device 262 on the supporting device 261 by turning the fixing member 2625 through the threaded hole 2626 into the slot 2612 to press the inner wall of the slot 2612 , or one of the positioning holes 2613 .
With reference to FIGS. 4 and 5 , the adjustable device 263 has two wings 2631 and a joint portion 2632 . The wings 2631 extend respectively from the sides of the joint portion 2632 , which form a gap 2633 between the wings 2631 . The gap 2633 receives the body 2621 . Each wing 2631 provides a guide slots 26311 and a locking notches 26312 . The guide slot 26311 extends along the wing's length direction, but has a bent segment 26313 at its end. The locking notch 26312 is at the end of the wing 2631 and above the guide slot 26311 . The guide pin 2622 has a head larger than the width of the guide slot 26311 , and passes through the guide slot 26311 , the guide pin hole 26212 and the other guide slot 26311 to be screwed into a nut 26221 . The user can tighten the nut 26221 to fasten the adjustable device 263 on the connecting device 262 or release the nut 26221 to allow the adjustable device 263 slidable or pivotable, relative to the connecting device 262 . The joint portion 2632 of the adjustable device 263 provides a threaded hole 26321 therethrough and generally perpendicular to its longitudinal axis.
The pressing device 264 includes a threaded rod 2641 and a pressing disk 2642 . The threaded rod 2641 is turned into the threaded hole 26321 in the joint portion 2632 and has a ball joint 26411 at its terminal. When turning the threaded rod 2641 , the length of the threaded rod 2641 down the threaded hole 26321 can be adjusted. The pressing disk 2642 has a ball seat 26421 accommodating and engaging unstably with the ball joint 26411 . Therefore, the angle between the ball seat 26421 and the threaded rod 2641 can change in a limited range. The bottom of the pressing disk 2641 may be rough and elastic to protect the surface of the workpiece from damage.
With reference to FIG. 7 , the notches 26312 of the adjustable device 263 and the first locking pins 2623 and the second locking pins 2624 of the connecting device 262 of the holding apparatus 260 have positional relationships described as follows. The guide slot 26311 is substantially defined along an imaginary straight line 2634 that passes through the guide pin 2622 . When the imaginary straight line 2634 is parallel to the operating surface 211 , the perpendicular distance between the first locking pin 2623 and the imaginary straight line 2634 is larger than the perpendicular distance between the locking notch 26312 and the imaginary straight line 2634 , but the perpendicular distance between the second locking pin 2624 and the imaginary straight line 2634 is equal to the perpendicular distance between the locking notch 26312 and the imaginary straight line 2634 . Therefore, when the adjustable device 263 is slid by the guide slots 26311 until the locking notches 26312 engage with the second locking pins 2624 respectively, the length direction of adjustable device 263 is parallel to the operating surface 211 , and the length direction of the pressing device 264 is perpendicular to the operating surface 211 . After tightening the nut 26221 to fix the adjustable device 263 on the connecting device 262 , turning the threaded rod 2641 will move the pressing disk 2642 to abut and press against the horizontal top surface 181 of a rectangular workpiece 180 perpendicular to the standing surface 221 for firmly holding the workpiece 180 in position.
With reference to FIGS. 8 and 9 , when the holding apparatus 260 is used to press a workpiece with an irregular profile, such as a triangular workpiece 190 , the adjustable device 263 is slid levelly, forward 26311 by the guide slots, relative to the connecting device 262 . When the guide pin 2622 gets into the bent segments 26313 of the guide slots 26311 , the adjustable device 263 is guided to move down inclinedly to avoid the surrounding of the locking notches 26312 hitting the first locking pins 2623 . The adjustable device 263 is pivoted about the guide pin 2622 downward and then pushed up inclinedly to make the locking notches 26312 engage with the first locking pins 2623 after the guide pin 2622 touches the terminal of the bent segments 26313 . Further, tightening the nut 26221 will fix the adjustable device 263 . Therefore, the length direction of the adjustable device 263 is accommodated for the inclined surface 191 of the triangular workpiece 190 , and the length direction of the pressing device 264 is substantially perpendicular to the inclined surface 191 . At the time, turning the threaded rod 2641 of the pressing device 264 can move the pressing disk 2642 toward the inclined surface 191 to abut against the inclined surface 191 . The triangular workpiece 190 will be firmly held for accurate cuts.
The holding apparatus 260 interconnects the connecting device 262 and the adjustable device 263 to allow the adjustable device 263 sliding and pivoting, relative to the connecting device 262 by the guide slots 26311 and the guide pin 2622 , and uses configuration of the guide pin 2622 , the locking pins 2623 and 2624 , the locking notches 26312 and the guide slots 26311 to fasten the adjustable device 263 on the connecting device 262 . Therefore, the holding apparatus 260 provides the purpose of changing the angle between the length direction of the pressing device 264 and the operating surface 211 so that the pressing disk 2642 can press the horizontal top surface 181 of a rectangular workpiece 180 or the inclined surface 191 of the triangular workpiece 190 . The holding apparatus 260 can help the power tool machine 200 accurately cut the workpiece that have rectangular or non-rectangular profile, or is placed in a tilted position. Moreover, the structure and the usage of the holding apparatus 260 are simple. Operation of the adjustable device 263 is quick and convenient.
It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents. | A power tool machine includes a base, a fence, a cutting arm, a motor, a saw blade and a holding apparatus. The base has an operating surface for supporting a workpiece. The fence mounted on the operating surface has a standing surface substantially perpendicular to the operating surface for abutted by a side of the workpiece. The cutting arm pivotally coupled to the base. The saw blade mounted to the cutting arm is rotatable by the motor. The holding apparatus includes a supporting device mounted on the base, a connecting device including a body connected to the supporting device, wherein a length direction of the connecting device is substantially perpendicular to a length direction of the supporting device, an adjustable device pivotally coupled to the connecting device, and a pressing device connected to the adjustable device for selectively pressing another side of the workpiece. | 8 |
SUMMARY OF THE INVENTION
This invention relates to a new textile product and specifically to a colored cellulosic textile product which can be treated employing methods which are adaptable for use either by textile mills or in home laundries to change the textile from its original color to a completely different color.
BACKGROUND
As will be readily apparent to those in the fashion industry, the ability to change easily and predictably the color of textiles in the form of garments, bed linens and other home furnishings, would be of great commercial significance. The ability to change the color of a favorite garment in one's own home would extend the range and life of the owner's wardrobe without significant cost.
The ability to effect color changes would also be of significant commercial and economic importance to textile mills and manufacturers. For example, knowing that the color of a given run of textiles produced for a particular season can be changed to colors for a following season would permit mills to establish large inventories for a longer selling season. As presently structured, the mills must dispose of their inventories of textiles in fashion colors by means of "close outs", which are often at a loss. With the ability to predictably and selectively change the colors of unsold inventory to other readily salable colors, or even to white, for printing, or redyeing, "close out" sales would become unnecessary.
The availability of textiles whose colors can be quickly and inexpensively changed would also permit smaller manufacturers to purchase two or more colors at the relatively large minimum yardage for single runs imposed by the large mills.
U.S. Pat. No. 3,030,227 describes a process in which a fabric is dyed with a dyestuff which is acid resistant and with a resin-bonded pigment susceptible to decomposition upon treatment with acid. In combination, the two coloring materials impart a certain color to the fabric. If it is desired to change the color, the fabric is treated with acid to decompose the resin-bonded pigment, leaving the fabric colored only by the acid resistant dyestuff.
The procedure of U.S. Pat. No. 3,030,227 is useful, but has a number of drawbacks. In the first place, the number of suitable dyestuffs or pigments available is rather limited so that a full range of colors is difficult to achieve. More importantly, the acids required for effecting the color change are not normally available to the consumer for use in home laundries. Finally the treatment leaves the textile with an offensive odor.
It is an object of the present invention to provide a method of changing the color of textiles, either in the form of garments and other finished products, or as piece goods, that can be practised quickly and easily using materials which are readily available to consumers.
It is a further object of the invention to provide a method of changing the color of textiles and garments which can be safely and simply practised by the consumer in the home laundry or local laundromat.
It is also an object of this invention to provide textile mills with a method of producing colored textiles which can be changed in color, or even returned to white, for printing or redyeing.
Another object of the invention is to provide textiles with the inherent capability of predetermined color change in order to permit garment manufacturers to obtain the benefit of large volume purchases from mills and thereafter vary the colors of portions of the textile to meet their seasonal inventory requirements.
DETAILED DESCRIPTION OF THE INVENTION
In about 1956 a new series of dyes termed reactive dyes began to appear on the market. These dyes, the first of which were based on a mono- or di-halo triazine nucleus, ##STR1## where X 1 is halogen, X 2 may be halogen or some innocuous substituent, and R is a radical including a chromophore group, are capable of reacting with a cellulosic substrate, thus actually binding the color to the substrate. Such dyes and variants thereof are now well known in the textile industry and are available from various manufacturers.
Reactive dyes differ one from another in their resistance to bleaching, and in particular, in their resistance to chlorine based bleaches such as those normally used in home laundries. Thus, for example, some typical reactive dyes have the following resistance to bleach, measured on a scale of 1 to 5 (with 5 indicating full stability to bleach under normal conditions).
______________________________________ BLEACHREACTIVE DYE RESISTANCE______________________________________Color Index Reactive Yellow 22 1Color Index Reactive Orange 86 4-5Color Index Reactive Yellow 86 2Color Index Reactive Orange 14 1Color Index Reactive Blue (conc.) 163 1Color Index Reactive Blue 4 3-4Color Index Reactive Blue 10 3Color Index Reactive Red 31 4Color Index Reactive Red 2 1Color Index Reactive Orange 4 4Color Index Reactive Brown 10 4______________________________________
Bleach resistance ratings are normally available from dye manufacturers. For example, the ratings for the above dyes which are "Procion"® dyes sold by Imperial Chemical Industries (ICI), are published by ICI.
In accordance with the present invention a cellulosic substrate is dyed with a combination of dyes, preferably reactive dyes, of different colors, at least one dye having high stability toward bleach (e.g., 4-5 on the above scale) and at least one being susceptible to decolorization upon treatment with bleach (e.g., 1-2 on the above scale). The dyed material is stable toward all treatments normally applied to colored fabrics; for example, it is stable to laundering using hot water and conventional soaps or synthetic detergents. However, when treated with conventional home bleach, for example, conventional aqueous hypochlorite solutions, the unstable dye is decolorized, leaving the stable dye to determine the color of the substrate. Thus, a complete shift in color can be accomplished using readily available materials which can normally be put to use by the consumer in the home laundry.
Certain vat dyes are also known to be stable to bleach and it is therefore possible to substitute a vat dye for the bleach stable reactive dye, in some circumstances. Preferably however both the dyes are reactive dyes.
The invention therefore comprises, in a first aspect, a colored textile material comprising a cellulosic substrate dyed with at least two dyes of different colors, one of said dyes being stable to bleach and the other being subject to decolorization by bleach.
In another aspect, the invention comprises a method of providing a textile product capable of having its color changed by domestic treatment which comprises dyeing a cellulosic substrate with two dyes, the first of which is stable to household bleach, while the other, having a different color from the first, is not.
Textile products which can be treated according to the invention range from yarns and threads to woven, nonwoven and knitted fabrics, as well as garments and other structures made from such products, provided that a portion of said yarns, threads or fabrics, is cellulosic. Such products are referred to herein as cellulosic substrates. The cellose component in the cellulosic substrate may be natural, such as cotton, linen, ramie, hemp, sisal or the like, or it may be synthetic, i.e., rayon made by the viscose, cuprammonium or other conventional process. The cellulose component may include cellulose esters such as cellulose acetate provided sufficient hydroxyl sites remain available for reaction with the reactive dye. In addition to the cellose component, the substrate may include various other textile components such as polyamide, polyester, acrylic or even polyolefin yarns or threads. Such materials may or may not be receptive to the reactive dyes and may themselves be colored in a union dyeing or cross dyeing procedure with some other species of dyestuff.
The substrate is originally dyed with the reactive dye or vat dye by any conventional method, following the instructions furnished by the dye manufacturer. For example, the dye may be applied by various continuous or batch dyeing operations, or by printing. Most reactive dyes are applied in the presence of an alkaline medium and after application are subjected to a steaming process to fix the dyes. The precise conditions will vary with the specific dyes and are readily ascertainable from the manufacturer's literature furnished with the dyestuff. By way of example, Procion® type reactive dyes are normally applied in an aqueous medium (which may be a printing paste) having a pH of between about 8.5 and about 11. Adjuvants such as thickening agents, migration control agents, mineral salts, for example sodium sulfate, and surfactants may also be in the dye mixture. The dye may be applied at a temperature of between about 20° C. and about 400° C. After a time which can range from as little as 10 seconds up to 120 minutes, the material can be steamed at 100° C. to 130° C. for from 30 seconds to about 10 minutes, washed with synthetic detergent and dried.
Vat dyes can be applied to the cellulosic substrate using established procedures on non-continuous machines or by padding methods. The vat dye pigments can be solublized in an aqueous medium by chemical reduction and then applied to the cellulosic substrate at a concentration which will produce the desired intensity of color. Thereafter, the substrate is washed in an acidified oxidizing solution to convert the dye back to the form of a water insoluble pigment and to develop the final color.
Alternatively, the vat dye may be obtained from the manufacturer in the form of the leuco compound, and the vatting step can be omitted. In this case, the dye is applied to the cellulosic substrate in aqueous solution, for example, by padding, followed by treatment to acidify and oxidize the compound in order to fix the pigment on the fabric and develop the desired color.
Where the dyes used are of the same type, the bleach stable dye or dyes and the decolorizable dye or dyes are applied together. On the other hand when different types of dyes are used, e.g., vat dyes and reactive dyes, the dyes are applied sequentially. It is of course also possible to apply two dyes of the same type sequentially.
The amount of each dye deposited is open to wide variation and is dictated by the colors desired for the textile after coloring and after the decolorizing treatment.
In order to determine the bleach stability of a particular dyestuff the following test procedure can be used:
A. A swatch of white cotton fabric, such as 100% cotton twill, or the like, is batch dyed in accordance with the instructions provided by the manufacturer of the dyestuff.
B. The dyed fabric is dried.
C. A solution of bleach containing 0.1% available chlorine is prepared. A piece of the dyed textile, weighing approximately 5 grams is placed in a container into which 100 ml. of aqueous bleach solution is added. The textile is immersed and allowed to stand for thirty minutes at 20° C. Thereafter the textile sample is removed, thoroughly rinsed and dried.
D. By visual inspection the treated piece is compared with a sample of the dyed fabric. If there is no perceptible difference, the dye is graded 5. If the fabric is white, or near white, the dye is graded 1.
In practicing the invention, when it is desired to change the color of a substrate dyed in accordance with the invention, the substrate is simply exposed to a conventional home bleach solution. Conveniently, this may be done by placing the substrate in a home washing machine of any available type, adding household bleach in the amount prescribed by the bleach manufacturer, a normal amount of any home detergent to serve as a wetting agent, and operating the machine in the usual manner. While it is believed that the above is sufficient to permit the average consumer to practice the invention, the various parameters of the treatment may be described more precisely as follows:
The substrate, such as a garment, is placed into contact with between about 5 kg. and about 10 kg. of water per kg of substrate. The water contains a conventional chlorine bleaching agent in an amount equivalent to a concentration of sodium hypochlorite of between about 0.2% and about 0.3% by weight. The precise agent used is not critical. Such readily available commercial products as Purex®, Clorox® and Javelle Water are entirely acceptable. A small amount of a detergent, say from about 0.5 to 1.0 ounces is also added. The purpose of the detergent is to wet the cellulosic fibers to accelerate the action of the hypochlorite to remove the chlorine-sensitive dye. The nature of the detergent, again, is not critical. It may be anionic, for example, an alkyl benzene sulphonate; non-ionic, such as ethylene oxide condensate; or blends of anionic and non-anionic detergents.
The color changing treatment is carried out at the temperature normally prescribed for the commercial bleaching agent. This will usually be between about 20° and about 30° C. The time of the treatment is again not critical, and may range from 10 to 60 minutes. After the treatment, the water remaining in the washing machine, or other container, with the substrate will normally appear colored. It should be noted that under the conditions of the normal home laundry, the color from the wash water, so far as it is due to reactive dye residues, will not affect other cellulosic materials which may be in the machine with the colored materials to be treated. The load may be drained, rinsed with clean water and dried. The colored garments or textile substrates will then be found to have assumed the color of the bleach stable dye (or combination of bleach stable dyes) with which they were treated when originally colored.
The invention will be further described with reference to the following specific examples which are intended as illustrative only.
EXAMPLE I
A series of samples of cotton fabric 12"×5" were pad dyed with aqueous solutions of various reactive dyes in the concentrations noted in Table I below to give a variety of different shades. The dyed fabrics were then placed in a Whirlpool® brand top loading home washing machine (about 16 gallons maximum water capacity) with sufficient white cotton garments to give a full load, and washed using approximately one cup of Tide® brand detergent and one cup of bleach (Clorox®). The machine was set on "hot". During the approximately 8 minute wash cycle, the water became dark colored. The machine continued through the following cycles following washing: spin-2 minutes; rinse-4 minutes; spin-2 minutes; rinse-4 minutes; and spin dry-6 minutes. After removal from the washing machine and drying the following changes were noted:
TABLE I______________________________________Sam- Concen- Orig-ple tration Bleach inal TreatedNo. Dyes (oz/gal) Ratings Color Color______________________________________A CI Reactive 6.02 1 Orange RoseYellow 22CI Reactive Red 11 0.60 4B Procion Yellow 1.61 4/5 Dark LightMX3RAProcion Blue MX-G 1.85 1 Green GreenC CI Reactive 2.60 1 Dark MediumYellow 22CI Reactive Blue 4 5.50 3/4 Green BlueD CI Reactive Blue 4 3.46 3/4 Dark SlateCI Reactive Red 2 1.41 1 Purple BlueE CI Reactive Red 11 1.68 4 Dark Cran-Procion Blue MX-G 0.93 1 Purple berryF CI Reactive 2.70 1 Dark Blue-Yellow 22 GrayCI Reactive Blue 4 2.60 3/4 GreenCI Reactive Red 11 0.75 4G Procion Blue MX-G 1.08 1 Dark TanProcion Orange 1.29 4 GreenMX-2R______________________________________
EXAMPLE II
Eight samples of 100% cotton broadcloth, measuring approximately 6"×36", and weighing about 4 oz./sq. yard were dyed with various reactive dyes and treated as described in Example I. The results are set out in Table II:
TABLE II______________________________________Sam- Concen- Orig-ple tration Bleach inal TreatedNo. Dyes (oz/gal) Ratings Color Color______________________________________H Procion Yellow 0.23 2 Navy PurpleMX-8GCI Reactive Red 11 0.672 4Procion Blue MX-G 3.17 1I Procion Yellow 0.42 4-5 Navy SlateMX-3$A BlueCI Reactive Red 2 0.60 1Procion Blue MX-G 2.64 1Conc.J CI Reactive Red 11 0.364 4 Navy LightCI Reactive Blue 4.48 Purple109(s)K Procion Yellow 0.665 2 Dark LightMX-8GProcion Blue MX-G 0.60 Green MintL CI Reactive Red 2 0.03 1 Navy DustyCI Reactive Blue 4 0.49 3-4 BlueProcion Blue 4.88 1MX-G Con.M Procion Yellow 1.87 4-5 Brown GoldMX-3RAProcion Scarlet 0.56 1MX-BRAProcion Blue MX-G 0.322 1Conc.______________________________________
EXAMPLE III
A series of eleven samples consisting variously of cotton twill, broadcloth, poplin and denim fabric measuring approximately 6"×36" were dyed with various reactive dyes and treated as described in Example I. The fabrics ranged in weight from about 2 oz./sq. yard for the poplins and broadcloth, up to about 10 oz./sq. yard for the twill and denim fabrics. The results are set out in Table III:
TABLE III______________________________________Sam- Concen- Orig-ple tration Bleach inal TreatedNo. Dyes (oz/gal) Ratings Color Color______________________________________N CI Reactive Blue 4 0.66 3-4 Med. Light Dark BlueProcion Blue 4X-G 0.10 1 BlueConc.O CI Reactive Red 11 0.378 4 Purple PinkProcion Blue MX-G 0.21 1concP Procion Yellow 2.40 4-5 Brown GoldMX-3RACI Reactive Red 2 0.60 1CI Reactive Blue 4 0.30 3-4Q CI Reactive Red 2 0.28 1 Purple BlueCI Reactive Blue 4 0.84 3-4R CI Reactive 0.84 1 Dark LightYellow 22CI Reactive Blue 4 2.00 3-4 Gray BlueS Procion Yellow 0.65 4-5 Red BrightMX-3RACI Reactive Red 2 1.00 1 YellowT Procion Yellow 0.375 4-5 Dark MediumMX-3RAProcion Orange 0.75 4 Green BrownMX-2RCI Reactive Blue 4 1.25 3-4U Procion Yellow 0.65 4-5 Dark LightMX-3RACI Reactive Red 11 0.80 4 Red PinkV Procion Yellow 0.36 4-5 Me- LightMX-3RA diumProcion Blue MX-G 0.17 1 Dark Avocado GreenW Procion Yellow 1.50 4-5 Black BrownMX-3RAProcion Orange 4.00 3-4MX-2RProcion Blue MX-G 6.50 1conc.______________________________________
EXAMPLE IV
Individual swatches of cotton broadcloth, measuring about 6.increment.×36" were batch dyed with reactive dyes and treated in accordance with the procedure of Example I. The results are tabulated in Table IV. In Table IV the concentration is given in terms of dye (solid) actually deposited on the fabric (% by weight of fabric).
TABLE IV______________________________________ Concen-Sam- trationple % weight Bleach Initial FinalNo. Dyes of fabric Ratings Color Color______________________________________AJ Procion Blue MX-G 4.00 1 Black RedCI Reactive 1.50 1Orange 14CI Reactive Red 11 2.00 4AK CI Reactive Blue 4 4.00 3-4 Black BlueCI Reactive 1.50 1Orange 14CI Reactive Red 2 2.00 1AL Procion Blue MX-G 4.00 1 Black YellowProcion Yellow 1.50 4-5MX-3RACI Reactive Red 2 2.00 1AM Procion Blue MX-G 4.00 1 Black OrangeProcion Yellow 1.50 4-5MX-3RACI Reactive Red 11 2.00 4AN CI Reactive Blue 4 4.00 3-4 Black GreenProcion Yellow 1.50 4-5MX-3RACI Reactive Red 2 2.00 1AO CI Reactive Blue 4 4.00 3-4 Black PurpleCI Reactive 1.50 1Orange 14CI Reactive Red 11 2.00 4______________________________________
EXAMPLE V
Swatches of 100% cotton twill (10 oz./sq. yard) fabric measuring 6"×36" were dyed with vat dyes. The vat dispersions were applied using the "pad-dry-chemical pad-steam-wash" process. Thereafter, the vat-dyed cellulosic substrates were further dyed with Procion reactive dyes using the procedure described in the manufacturer's instructions. The treated swatches were then cut in two, and one part of each was treated with bleach in accordance with the procedure described in Example I. Results are tabulated in Table V.
TABLE V______________________________________Sam- Concen-ple tration Bleach Initial FinalNo. Dyes (oz/gal) Ratings Color Color______________________________________AP CI Vat Blue 6 5 4-5 Green BlueCI Reactive 2 1Yellow 22AQ CI Vat Blue 6 5 4-5 Purple BlueProcion Scarlet 2 1MX-3RAAR CI Vat Blue 6 5 4-5 Garnet BlueCI Reactive Red 2 2 1AS CI Vat Yellow 2 6 4-5 Orange YellowCI Reactive Red 2 0.6 1AT CI Vat Yellow 2 1.7 4-5 Green YellowProcion Blue MX-G 1.9 1Conc.AU CI Vat Red 10 6.7 4-5 Purple RedProcion Blue MX-G .6 1conc.AV CI Vat Red 10 6 4-5 Orange RedCI Reactive 1Yellow 22______________________________________
When blends of cotton and polyester are used, the dyed samples differ in shade from the pure cotton fabrics because the polyester fibers do not accept the vat dye or the reactive dye and therefore undergo no discernible color change. This fact can be employed to create additional ornamental effects and color changes in such cotton blends. | Textile products comprising a cellulosic substrate are colored with two or more dyes which differ in their respective resistance to chlorine bleaches. The initial color of the textile is determined by the combined effect of the dyes. Thereafter, textile products which may be in the form of garments, bed linens, draperies, or yard goods, are treated with an aqueous solution of bleach to decolorize, to a pre-determined degree, one or more of the dyes, to thereby change the color of the textiles. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a 35 U.S.C. §371 national stage application of PCT Application No. PCT/NO2008/000267, filed 16 Jul. 2008, and entitled Detector System and Method to Detect or Determine a Specific Gas Within a Gas Mixture, hereby incorporated herein by reference, which claims priority to Norwegian Patent Application No. 2007 3690, filed 17 Jul. 2007, hereby incorporated herein by reference.
STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
TECHNICAL FIELD
The present invention relates to the field of gas detection. Specifically, the invention relates to gas detectors with low energy consumption, especially for application in areas which are dangerous with respect of gas explosions.
BACKGROUND AND PRIOR ART
Specifically on oil productions platforms and in industrial plants where hydrocarbon is handled and processed, it is important to be able as soon as possible to detect the existence of combustible gases which are leaking. In fact, more than fifty percent of gas leaks recurring on oil platforms are today detected manually. Such detection is of an incidental type and shows that there is a need for installation of more gas detectors. Gas detectors to be used on oil platforms have to fulfill stringent technical requirements. They have to be extremely reliable, sensible, EX approved and must be able to exist in harsh weather conditions over time. High technology equipment exist which can fulfill the requirements, but for extremely high price per detector and with considerable installation costs, among others because they have to be linked with fixed wiring to a central. This limits coverage of an area. Cheaper gas detector types are desirable.
It is thus an advantage that the detector arrangement is of wireless type, specifically because of the installation costs. Then it is at a same time of interest to use separate power supply for each detector arrangement, e.g. a battery supply. But it is at the same time necessary that the detector is “ON” continuously and conventional gas detectors typically draw so much current that battery operation becomes impractical or impossible.
Specifically advantageous are gas detectors of the type which are able to perform a precise determination of the concentration of a specific gas type, e.g. detector for methane have a considerable higher energy consumption than a more “unspecific” detector which can detect changes in a gas mixture, but can not determine for sure which gas has been added to the mixture.
(Examples for unspecific detector types are acoustical sensors with electrostatic, electromagnetic or piezo-electrical activation. Examples for specific detector types are photo acoustical sensors and other infrared sensors which can be made specific for e.g. methane, C 3 H 8 , CO 2 , natural gas).
Other areas of interest with respect to disposal of the gas detector are limited areas within a manhole or tanks on vessels and down in mines lacking electricity and data communication and where one can not have fixed detector installations.
There is thus a need for a detector which both are really energy efficient and which gives good measurements of the specific gases which are considered to be dangerous in a given area.
An example of prior art is disclosed in the Patent Application EP 1 316 799 A2, where a gas detector for a specific gas is used to control a ventilation system. This publication relates mostly to algorithm for calculation of threshold values for activation.
The International Patent Application WO 00/16091 A1 describes a gas sensor group for a number of specific gases where control devices for the single gas sensors are powered down and up by a multiplexer to avoid crosstalk of signals from single sensors.
The Patent Applications US-2004065140 A1, GB-2364807 A, JP-2002109656 A and U.S. Pat. No. 6,321,588 B1 show systems and methods used to monitor changes in gas concentrations or gas leaks at hardly accessible places in industrial plants. These comprise at least one sensor and energy saving methods by sensors and other components being able to be powered down or the use of pulsed batteries.
These examples of prior art in the field do not solve the problem which is described above. The present invention seeks to satisfy the above mentioned need for reasonably priced and energy efficient gas detectors.
SUMMARY OF THE EMBODIMENTS OF THE INVENTION
To solve the above mentioned problems and to satisfy the above mentioned need, in accordance with the present invention it is provided embodiments of a detector system to detect or determine at least one specific gas in a gas mixture, where the specialty of the detector system is that it comprises
at least one first detector which continuously monitors the gas mixture to detect a change in the composition of the mixture, and at least one second detector with the ability to determine the concentration of the at least one specific gas in the gas mixture wherein the second detector is arranged to be activated when the first detector detects the change.
Favorable and preferred embodiments of the detector system according to the invention appear from the attached patent claims.
The embodiments of the present invention comprise also a further aspect. The second aspect is carried out by a method to detect or determine at least one specific gas in a gas mixture, and the special features of the method is that it comprises the following:
the gas mixture is monitored continuously with at least one first detector to detect a change in the composition of the mixture, at least one second detector is activated when the first detector detects the change and the second detector performs the determination of the concentration of the at least specific gas in the gas mixture.
Favorable and preferred embodiments of the method according to the invention will appear from the attached patent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will be described below, and a reference to the attached drawings is given where
FIG. 1 shows a block diagram for a principle embodiment of the detector system according to the invention,
FIG. 2 shows the functional diagram about the cooperation between the detectors in the system, and
FIG. 3 shows a specific embodiment of the detector system according to the invention with a separate controller as link between groups of first and second detectors.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a schematic diagram of a first embodiment of the invention. The main blocks are a first gas detector D LP with necessary equipment as electronic and sensor, and disposed close to D LP a second gas detector D HP with corresponding necessary equipment. D LP requires little power supply P L from the energy supply B, while D HP in active state requires more energy supply P H from the power supply B. The sensor in the first detector D LP is able to detect changes in the gas composition in the ambient atmosphere (which is not limited to the natural atmosphere, but may be any present gas mixture in the environment the detector is monitoring), but is not necessarily able to distinguish different specific gases. It does not even need to be very reliable in the sense that it may give wrong detections. The other gas detector D HP is arranged to measure the concentration of a specific gas, or some specific gases which are considered to be important to control in the actual environment, and it is thus activated by the first detector D HP only when the latter detects changes in the atmosphere composition. The “specific” detector or sensor D HP is of a type which uses larger amount of energy P H than the first detector D LP , but is inactive most of the time. If this second detector D HP confirms the detection of the first detector D LP (i.e. finds a sufficient high concentration of the actual dangerous gas) it sends a message over a signal link L to a receiver R. In a special embodiment, the communication of the result of the analysis to the receiver R is performed using a radio link according to the Zigbee standard.
An embodiment of the invention is a control unit CU linked to the other detector D HP as shown in FIG. 1 . The control unit is arranged to assess the outgoing signal from the detector D HP which represents a measured concentration level for the actual specific gas (or several outgoing signals for specific gases). The control unit CU is made up advantageously by a micro processor. It can be a separate unit with signal link via a wire, it can be co-located with the gas measuring unit D HP or it can use a radio link. In such a case the “specific” detector/measuring unit D HP must be equipped with a radio transmitter. This further increases the current draw of the detector, but can be acceptable because, as mentioned above, we are talking about short time activity periods for the detector D HP .
Thus, in such a case as mentioned above, the control unit CU may be co-located with the receiver R, i.e. the receiver R can thus be looked upon to be a part of the control unit CU (i.e. to the contrary of what is shown in FIG. 1 ).
One function of the control unit CU can be to deactivate the second detector D HP right after a measurement showing a non-dangerous concentration level for the one or the several specific gases by sending the activation signal back to D HP . (In an alternative embodiment without control unit, D HP can have an integrated timer which deactivates automatically on time out).
Another function of the control unit CU is to emit a signal to the outside when the measured concentration level is within a dangerous range, i.e. the signal to an remote receiver unit R as shown in FIG. 1 . The signal is transmitted over a communication device L which can be a radio link, preferably of a short range type with low emitted effect, or an optical link through the atmosphere or through fibre. Then there must be disposed necessary transmitter and receiver equipment of generally known type, a control unit CU and receiver unit R. (In an alternative embodiment without control unit, the D HP itself may have integrated miniature transmitter which transfers signal which represents the measured value to receiver R).
Anyway such a control unit CU has stored certain threshold values for concentration in the atmosphere for the actual specific gases and the control unit will test the measured values against the threshold value to decide whether a deactivating of D HP shall be done, or whether a signal shall be issued to the receiver R. (NB: In order to not consuming more power than necessary in the case with a signal transfer from the control unit CU to the receiver unit R 1 it is possible to deactivate the second detector D HP again, e.g. if the measuring value does not show a further fast increase. It would be possible to apply an algorithm for “reasonable deactivation” even after a measured over-concentration. A new activation can then happen after a given time).
As a further development step of the control unit CU it can contain a recording and storing unit for values for measured gas concentrations. Such a recording unit can alternatively be disposed within the receiver R.
A natural function in connection with the gas detection system in an area where personal and/or expensive equipment is located, is an immediate alarm signal which can be followed up by surveillance personal. Such alarm and warning equipment can be disposed in the receiving unit R, typically in a surveillance-central. Or it can be integrated in the control unit CU or in the second detector D HP itself. Such alarm devices can comprise warning lights e.g. of a flashing type, sound sources in the form of hooters or alarm horns, as well as vibration equipment for receiving units being worn by persons.
Furthermore the receiving unit R can also be linked to the equipment which immediately assures a close-down of production or process equipment in the area where the alarm giving detector system is disposed, generally independent of if there is used equipment for giving an alarm which is sensible for humans.
It was mentioned above that the control unit CU can be linked wirelessly to the second detector D HP to receive a signal from the detector. The radio link can also operate the other direction e.g. a relation to the deactivation function, and D HP thus must have an integrated radio receiver.
In an embodiment of the invention a single control unit CU serves a number of the second detectors D HP . A function of the control unit CU is to be reprogrammable with respect to single threshold values both for specific gases which shall determine with respect to concentration, and for single units of the second detectors D HP . If the control unit CU is disposed in a central and together with—integrated with or as a replacement for the receiver unit R,—such threshold values could be set by an operator.
As mentioned above according to the present invention, the detector system can be used for detection of gas leaks on oil platforms and in process plants for hydrocarbons, i.e. oil and gas, which is transported and processed in large quantities. In this case it is important to monitor the natural atmosphere in situ such that gas leaks to the ambient can be detected sufficiently fast. In this case we are talking about detecting hydrocarbon gases, e.g. methane, which also can give an explosion risk.
The detector system according to the invention can also be disposed in different environments and for measuring different dangerous gases, e.g. gases wherein chlorine is a component, fluoride carbon gases, hydrogen, oxygen, hydrogen sulphide, carbon monoxide and carbon dioxide. In addition helium, water vapour and SF6-gas is of interest.
An issue with the present invention is as mentioned above, to achieve a continuous but energy saving detection, and this is achieved by the principle that a non specific gas detector consuming little energy is working continuously and wakes up a specific detector whenever a change is detected, and the specific detector then measures the concentration of the specific gas before it is deactivated again. Thus, the specific detector which consumes more energy is only active in short periods. This means that the system can work long with battery operation.
The detector D LP can include a sensor of a type which detects that an average and thus unspecific molecular weight for the actual gas mixture in situ is changes. This unspecific detector should be “super sensible”, i.e. that it gives alert more often than really necessary, but never drops an alert about a change, i.e. even minor changes will result into a wake-up of D HP .
The first detector D LP can advantageously comprise a sensor of a type which uses a micro acoustical sensor principal, with electrostatic or piezo-electrical activation.
It is further also possible as an alternative, to use a first detector D LP which is specific in relation to a distinct gas, as long the detector is suitable for continuous battery operation, i.e. it is drawing sufficiently little power. Such a detector will be of a type with low precision with regard to the measurement and frequently give false alarms, but this does not mean too much. Example for sensor types in such a detector are for indication of methane, metal-oxide-semi-conduct-sensors and electrochemical cells.
As an example for suitable non-specific sensors with low energy consumption to be used in the detector D LP , in a preferred embodiment a miniature gas sensor as described in the Norwegian Patent 323259, granted 2007 Feb. 19, can be used.
Regarding the other, specific detector D HP it comprises in a favourable embodiment of the invention a sensor which works on the basis of the ability of the specific gas to absorb infrared radiation. So called NDIR-gass sensors (Non-Dispersive IR-) and photo acoustical sensors are candidates, specifically miniaturized detectors made by semiconductor technology. Please refer in this connection to the Norwegian Patent No. 321281 (granted 2006 Apr. 18), which shows a light source specifically well suited for such detectors.
In a specific embodiment the second detector D HP has an integrated intelligence represented by a micro processor with the function to chose which distinct gas to be measured (among a preset set of gases), depending on a signal level or signal type from the first detector D LP . If the first detector immediately emits a signal which indicates a substantial change in the composition, this can be interpretted as a big leak of a substantial gas component, and it can mean that distinct gas should be checked first. In case of a less intense starting signal, a different sequence could be of interest.
It is a prerequisite in this case that the single second-detector D HP has the ability to measure a number of specific gases. This is possible to achieve and is realized e.g. by multi sensors of the IR-type, where the actual gases are contained in one chamber per gas with a window.
Talking about several first- and second-detectors the integrated processor-intelligence can on the basis of which first-detector DHP giving the triggering signal, decide which detectors DHP to be activated and to perform the concentration measurement. The processors at the second-detectors DHP can handle such a decision by recognizing of the signal from the single first-detector DLP.
FIG. 2 shows the functioning of the detector system according to the invention. A non-specific detector with the sensor S LP in the left part of the figure with low energy consumption, monitors in a endless loop a gas mixture—which can be the ambient atmosphere, but also a gas mixture in a pipeline or similar—and checks if the composition of the mixture stays constant or changes. (Possibly it can monitor the concentration level of a specific gas, as mentioned above). As far as the composition stays constant, the detector will continue with this monitoring without any additional action. If, however, the composition is changed in a detectable magnitude, a sensor S HP is activated—Wake up—in a detector in the right side of the figure which performs—with higher power consumption—a specific analysis. If the result of this analysis e.g. shows that the percentage of hydrocarbons HC in the gas mixture is lower or equal 2500 ppm, this means that the unspecific sensor S LP has made a fault measurement, or that the detected change in the composition of the gas mixture is related to something different than a decrease of HC, or eventually that there has been a change of HC which does not exceeds the limit for what is considered dangerous. The right detector mend the powers itself to reduce the power consumption of the total system. If, however, the estimation of the left detector is confirmed by measuring higher concentrations of hydrocarbons than e.g. 2500 ppm, an alarm is given.
FIG. 3 shows another embodiment of the invention. Here a “link” between the first-detector D LP and the second-detector D HP is introduced in the form of a controller CU 2 . This controller CU 2 which comprises a micro processor and transmitter/receiver equipment of the type which is chosen as a wireless link between the units (e.g. short range radio) may have the task to sort the incoming signals from single first-detector D LP to decide which specific gas shall be used to determine the concentration with all second-detectors D HP or with specific single ones of these. CU 2 , which preferably can be disposed in a central, has an overview over the placement of each single detector in the system, and can reprogrammed by the personal in accordance with the changes e.g. disposition of new detectors, changes of threshold levels and more. It is assumed that all detectors are equipped with transmitter/receiver equipment.
As can be seen in FIG. 1 , in a simple embodiment of the invention with two proximate displaced detectors D LP and D HP both have power supply from a common battery B. This will be the typical form for power supply, but one would not limit one self to battery power supply. In locations with “harvestable” energy forms such as sunlight, wind or continuous vibrations, it is possible to set up an energy collecting system which supplies the detectors. One could not exclude the possibility to use known types of uninterruptible power supplies.
Above the assumption was made that the first, non-specific detector D LP and the second specific detector D HP were localized close to each other. This can in a specific embodiment mean that they are assembled together and can be delivered as a unit, even as a miniaturized type. But, in different embodiments of the detector system according to the invention where several detectors are utilized, they likely can be placed in different locations. In this case one can define an oil platform as one place even if detectors of the two different types are disposed with several tens of meters distance from each other. Such a placement can make that a CU or CU 2 have a picture of how a specific gas or several specific gases are spreading. | To achieve gas detection in a precise and reliable way, but at the same time without consuming too much energy, a gas detection system is provided which generally comprises a pair of two different gas detectors. The first detector (D LP ) is active continuously and sense substantially for an unspecific change in the local gas mixture. As a reaction upon the change, the second detector (D HP ) of the pair is activated. This detector (D HP ) performs the determination of the concentration of a specific gas or several specific gasses. The second detector (D HP ) may be of a type which consumes more power, but will be active for a short period of time before returning to an inactive state where only the first detector (D LP ) is active. The first detector (D LP ) however is of a type using little power. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a print service system for providing print services at a print service shop having an output apparatus such as a printer, in response to a user request.
2. Related Background Art
When a user prints electronic image/document at a print service shop having an output apparatus such as a printer, the user supplies a storage medium storing electronic data or connects a user terminal such as a personal computer to the output apparatus, to print the electronic data stored in the storage medium or in the user terminal.
A user may connect a user terminal at an office or home to a print server via a network such as the ISDN network to transmit electronic image/document via the print server to a print service shop to print out the electronic data.
SUMMARY OF THE INVENTION
As compared to direct printing by connecting a user terminal to a printer at a print service shop, indirect printing via a print server requires an additional communication fee for transmitting electronic document data from the user terminal to the server and to the print service shop.
If the charging system uses always both a printer use fee and a communication fee irrespective of service types, a user is required to make a settlement by paying both the fees, which is not convenient for the user to use the system.
The invention has been made to solve such conventional technical problems and aims to provide a print service system capable of improving user settlement convenience by setting a charging system depending upon each service type.
With a conventional print service system, a fee per one copy is discounted depending upon the number of output copies, or discounted to a member fee for a registered user.
With this system, the fee is discounted simply depending upon the number of output copies or to the member fee, irrespective of how many times a user uses a printer. Therefore, a user who frequently uses a printer has no merit.
The invention has been made to solve such conventional technical problems and aims to provide a print service system capable of dynamically determining a fee depending upon the past use records of a user to provide services specific to each user.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing the outline structure of a first print service system according to an embodiment of the invention.
FIG. 2 is a diagram showing the outline structure of a second print service system according to an embodiment of the invention.
FIG. 3 is a diagram showing the outline structure of a third second print service system according to an embodiment of the invention.
FIG. 4 is a block diagram showing the functions of a print service server.
FIG. 5 is a block diagram showing the functions of a print service shop.
FIG. 6 is a diagram showing a print service sequence when a user terminal accesses a print service server.
FIG. 7 shows an example of a display window on a user terminal.
FIG. 8 is a diagram showing a print service sequence when a user terminal directly accesses a printer at a print service shop.
FIG. 9 is a flow chart illustrating the outline of a process of updating a user charge management attribute.
FIG. 10 is a diagram showing an example of the structure of log data including user use records.
FIG. 11 is a diagram showing an example of a service use record management table before being updated.
FIG. 12 is a diagram showing an example of a user charge management attribute reference table.
FIG. 13 is a diagram showing an example of a service use record management table after updated.
FIG. 14 shows an example of a display window on a user terminal.
FIG. 15 is a flow chart illustrating a royalty updating process for a print service shop.
FIG. 16 is a diagram showing an example of the structure of log data including operation records at each print service shop.
FIG. 17 is a diagram showing an example of a printer use record management table for each print service shop before being updated.
FIG. 18 is a diagram showing an example of a contracted shop royalty reference table.
FIG. 19 is a diagram showing an example of a printer use record management table for each print service shop after updated.
FIG. 20 shows an example of a display window on a user terminal at a print service shop.
FIG. 21 is a flow chart illustrating the outline of a print service shop selection service process.
FIG. 22 is a diagram showing an example of a shop information table.
FIG. 23 shows an example of a display window on a user terminal.
FIG. 24 shown an example of a display window on a user terminal showing the location of a shop on a map.
FIG. 25 is a flow chart illustrating the outline of a fee computation process.
FIG. 26 is a diagram showing an example of the structure of log data including user service use types.
FIG. 27 is a diagram showing an example of a service type standard unit fee.
FIG. 28 is a flow chart illustrating the outline of a settlement process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the invention will be described with reference to the accompanying drawings.
(Outline Structure of Print Service System)
FIGS. 1 to 3 are diagrams showing the outline structures of a print service system according to the embodiments.
Referring to FIG. 1 , a print service server 100 is a personal computer (PC) or a Web server and manages the whole of print services. A user charge process and a service shop settlement process are managed as a general rule by the print service server 100 .
A print service shop 101 has a printer 101 a , a PC connected to the printer 101 a via a LAN, and the like. The print service shop 101 provides users with print services.
A user terminal 102 may be a PC at a user office or home. It is desired that the user terminal 102 is connectable to the Internet via a telephone line or ISDN line and has a Web browser for analyzing an HTML document and displaying it on a display screen. A user accesses the print service system by using the user terminal 102 .
In this example, although the system has one user terminal 102 and one print service shop 101 , it is obvious that the system is applicable to a plurality of users and shops.
If a plurality of print service servers 100 are set and a means for transferring data between servers a is provided, the system performance can be improved and a system having higher reliability can be realized.
The operation type of each print service system shown in FIGS. 1 to 3 will be described.
In the system shown in FIG. 1 , the user terminal 102 , print service shop 101 and print service server 100 are interconnected by the same network. More specifically, they are connected to the Internet and a user accesses the print service server 100 and instructs the print service server 100 to print a designated document at the print service shop 101 . The charge management is performed by the print service server 100 .
In the system shown in FIG. 2 , a mobile telephone is used as the user terminal 102 which is prevailing nowadays and has a function of a data terminal. The fundamental service type is similar to that of the system shown in FIG. 1 . In this system, a user connects the user terminal 102 to a gateway server of a mobile telephone carrier via a mobile telephone network, and to the Internet via the gateway server. The gateway server can perform user verification, charge and the like.
In the system shown in FIG. 3 , as a user terminal 102 , a portable PC such as a so-called note type PC is used. A user directly connects the user terminal 102 to a system of the print service shop 101 via a Centronics cable or the like, and a printer 101 a directly handles a print request from the user terminal 102 . Also in this system, the charge management and the like for each user can be performed collectively at the print service server. In this case, the printer 101 a or a PC connected to the printer 101 a transfers charge information of each print request to the print service server 100 .
In operating the system, an access means to the print service server 100 is installed basing upon mainly a general Internet protocol (HTTP or the like), and security is ensured by using a general means typically an SSL (Secure Socket Layer).
A connection means between the print service shop 101 and user terminal 102 is installed by using general parallel or serial connection.
FIG. 4 is a functional block diagram of the print service server 100 of the embodiments.
The print service server 100 is mainly constituted of: a communication controller 401 ; an information provider 402 ; a job accepter 403 ; a job distributer 404 , a data converter 405 ; an operation manager 406 ; a result accepter 407 ; a fee computer 408 ; and a settlement maker 409 , as well as a data management apparatus group comprising a verification information unit 451 ; a contract information unit 452 ; a fee system unit 453 ; a log information unit 454 ; a job unit 455 ; a document information unit 456 ; a settlement information unit 457 ; and a shop information unit 458 . The print service server 100 constitutes a print service management server.
The communication controller 401 performs a data communication process for the user terminal 102 , print service shop 101 and the like. A user verification process and the like are performed by using data managed by the verification information unit 451 .
The information provider 402 searches requested data from various data managed by the server 100 and generates data to be sent back to the requester. The communication controller 401 and information provider 402 constitute a communication means.
The job accepter 403 accepts job data (mainly print request) from a user, the job data being managed by the job unit 455 . The job accepter 403 also accepts a document registration request from a user, data regarding the document registration request being managed by the document information unit 456 .
The job distributer 404 sequentially transfers job data still not processed and under management by the job unit 455 to the designated print service shop 101 .
The data converter 405 performs a conversion process of converting, when necessary, the data format of job data or the like so as to match the print process performance of the print service shop 101 to which the job data is distributed.
The operation manager 406 performs registration, update and the like of user management data, shop management data, fee management data and the like necessary for providing and operating services for the data management apparatus group.
The result accepter 407 accepts a result of a job executed at the print service shop, and in accordance with the result contents, updates the job management data in the job unit 455 and resisters the log information in the log information unit 454 .
The fee computer 408 computes a fee to be claimed to the job result in accordance with various charge conditions, settlement data being managed by the settlement information unit 457 .
The settlement maker 409 performs a settlement process for a charge depending upon user use records, a pay settlement process and royalty settlement process for each print service shop, and the like.
The data management apparatus group operated and managed by the server will be described supplementarily. Each data management apparatus or unit is constituted of a storage unit such as HD.
The verification information unit 451 manages data to be managed under sufficient security, such as a password and a settlement account number corresponding to a user ID. For a user whose access is to be denied, such as a user without a contract period updating process and a user whose fee is not paid even after the due date, an attribute representative of an access denied user is also managed by the verification information unit 451 .
The contract information unit 452 manages data including each contracted user attribute (user name, address, contact location or the like), contract contents (contract period), settlement means (credit card, bank transfer, or the like), discount rate depending upon use records and the like.
The fee system unit 453 manages a standard fee table for each service, a user charge management attribute reference table which is used as a calculation reference to various charge process services depending upon use records, a contracted shop royalty reference table which is used as a reference to royalty calculation of each contracted shop depending upon service records, and other tables.
The log information unit 454 sequentially records and manages as to who issued a lob to which shop and what was the result, and the like, respectively of each service.
The job unit 455 manages a job received from a user to sequentially perform a job process. The job unit 455 stores a priority degree of each job to perform job scheduling, accepts a job with a designated execution time, and stores job data to be later executed again.
The document information unit 456 can perform registration, management, search and the like of a document upon request from a user.
The settlement information unit 457 manages data for settlement of service execution including a settlement process state.
The shop information unit 458 manages various shop information.
FIG. 5 is a functional block diagram of a shop system constituted of a printer 101 a and PC installed at a print service shop of the embodiments.
A print service shop system 101 is mainly constituted of: a communication controller 501 ; an information provider 502 ; a job accepter 503 ; a job processor 504 ; a data converter 505 ; an operation manager 506 ; a result informer 507 ; a fee collector 508 ; and a printer 509 , as well as a verification information unit 551 ; a contract information unit 552 ; a fee system unit 553 ; a log information unit 554 ; a job unit 555 ; and a document information unit 556 , respectively constituting a data management apparatus group. Each unit such as a PC including each constituent element excepting the printer 509 constitutes a shop service management unit.
The communication controller 501 performs a data communication process for the user terminal 102 , print service server 100 and the like.
A user verification process and the like are performed also by the communication controller 501 when a user terminal is connected directly to the print service shop system 101 . Data of a particular user having a high use frequency is transferred from the print service server to the verification information unit 551 of this system so that the system can directly perform the verification process by using the transferred data. However, in a usual case, the verification process is performed by the print service server.
The information provider 502 searches requested data from various data managed by this system and generates data to be sent back to the requester.
The job accepter 503 accepts job data (mainly print request) directly from a user or from the print service server, the job data being managed by the job unit 555 .
The job accepter 503 also accepts a request for registering a document registration in this system from a user, data regarding the document registration request being managed by the document information unit 556 .
The job distributer 504 sequentially transfers job data still not processed and under management by the job unit 555 to the printer 509 to execute the job, and in accordance with the job execution result, the job management data in the job unit 555 is updated and registered in the log information unit 554 .
The data converter 505 performs a conversion process of converting, when necessary, the data format of job data or the like so as to match the print process performance of this system.
The operation manager 506 performs registration, update and the like of fee management data and the like necessary for providing and operating services for the data management apparatus group.
The result informer 507 notifies the print service server of a result of the executed job. The result informer 507 constitutes a history information notifying means.
A fee collector 508 is used for the system to collect a charge amount to be claimed for the job result by means of cash, prepaid card or the like.
The printer 509 has not only a monochromatic image and color image printing function and a both-side printing function but also an additional service function such as a binding function. The printer 509 corresponds to the printer 101 a.
The data management apparatus group operated and managed by this system will be described supplementarily.
The verification information unit 551 is similar to that of the print service server in terms of function. However, the print service shop system can manage data of only a particular fixed user under contract.
The contract information unit 552 manages various contract contents, operation condition data and the like respectively of fixed users.
The fee system unit 553 manages data such as charge service conditions specific to the shop, the data being stored also as the shop information of the print service server.
The log information unit 554 sequentially records and manages as to who issued a job to which shop and what was the result, and the like, respectively of the service supplied at the shop.
The job unit 555 manages a job received from a user to sequentially perform a job process.
The job unit 555 stores a priority degree of each job to perform job scheduling, accepts a job with a designated execution time, and stores job data to be later executed again.
The document information unit 556 can perform registration, management, search and the like of a document upon request from a user.
(Fundamental Process Flow of Print Service)
FIG. 6 is a diagram showing an example of a print service sequence according to the embodiment, and FIG. 7 shows an example of a display window on a user terminal.
FIG. 6 is a diagram showing the print service sequence when a user terminal 102 accesses the print service server 100 and asks the print service shop 101 for printing. The fundamental process flow will be described.
When the user terminal 102 issues a login request to the print service server 100 (S 601 ), the server 100 performs a verification process (S 602 ) and notifies an access permission or inhibition.
Next, if a search request for a document stored in advance in the server 100 is issued (S 603 ), the server 100 performs a requested document search process and notifies the search result (S 604 ).
When a search request for available shop information is issued (S 605 ), the server 100 performs a process of searching shop information from the shop information under management, in accordance with the requested search conditions, and notifies the search result (S 606 ).
A user designates, if necessary, a document to be printed, a shop, print conditions supported by the print service shop, and the user terminal 102 transmits a print request to the print service server 100 (S 607 ). The server 100 first confirms whether there is any problem of the user settlement status (S 608 ), and then accepts the request (S 609 ).
FIG. 7 shows an example of a display window on the user terminal. The user terminal 102 displays a search result list of documents registered in advance by the user in the print service server 100 , and the user selects and identifies the document to be printed.
When a print requested job is distributed to a predetermined shop (S 610 ), the shop 101 accepts the job (S 611 ).
After the job is processed (S 612 ), the job result is notified to the server 101 (S 613 ).
After the server 100 accepts the job result (S 614 ), the server 100 executes a fee computation process (S 615 ) to make settlement (S 616 ), and the settlement data is registered in the log (S 617 ).
FIG. 8 is a diagram showing a sequence when the user terminal 102 directly accesses the print service shop 101 and processes the print request in cooperation with the print service server 100 . The fundamental process flow will be described. This sequence is applied, for example, to the case wherein a user with the user terminal 102 visits the service shop and connects the user terminal 102 to the printer 110 a and PC of the print service shop.
When the user terminal 102 issues a login request to the print service shop system 101 (S 801 ), the print service shop system 101 performs a verification process (S 802 ) to notify a print permission or inhibition. In this case, the print service server 100 may be asked for the verification process if necessary (S 803 ).
When the user terminal 102 issues a document print request by designating, if necessary, print conditions supported by the print service shop system 101 (S 804 ), the shop system 101 confirms whether there is any problem of a user settlement status (S 805 ), and then accepts the document print request (S 807 ). At this time, the user terminal 102 transmits print data (document data) to be printed as well as the document print request to the printer 101 a . If necessary, the server 102 is asked for the settlement status to perform the confirmation process (S 806 ).
If the document is registered beforehand in the print service shop system 101 , the document is searched and designated to print it out.
After the job is processed (S 808 ), the job result is notified to the server 100 (S 809 ) which receives the job result (S 810 ) and executes a fee computation process (S 811 ) and then a settlement process (S 812 ). The settlement data is registered in the log (S 813 ).
(Charge Management Attribute Update Process Depending Upon User Use Records)
Means for providing various services depending upon user use records will be described, which means is used for promoting use of services and is characteristic to the present invention. FIG. 9 is a flow chart illustrating the outline of a process of updating various user charge management attributes (such as a discount rate of a base fee) in accordance with user use records.
First, user use records are acquired from log data (S 901 ). FIG. 10 shows an example of log data managed by the log information unit 454 . FIG. 10 shows use records as of March 2000, with a user ID, a date of use, and a fee.
FIG. 11 shows a service use record management table before log data managed by the contract information unit 452 is acquired. Since the use records of March are not recorded in the table shown in FIG. 11 , log data shown in FIG. 10 is the use records of March. Namely, a use fee of Okuda in March is 2,450 Yen and a use fee of Yamada in March is 12,100 Yen.
Next, a discount rate of a use fee is determined from the acquired data and the contents of the user charge management attribute reference table managed by the fee system unit 453 (S 902 ).
A user having larger use records is provided with more discount services.
FIG. 12 shows an example of the user charge management attribute reference table managed by the fee system unit 453 . In this example, the table is used for determining a base discount rate, a term of settlement, a credit accepted and the like from use records of the previous month. Use records may be managed in the unit of three months, half year or the like.
In the example of the log data shown in FIG. 10 , a base discount rate of Okuda is 1% and that of Yamada is 5% according to the use records of March.
Similarly, the term of settlement of each user is determined (S 903 ).
It is judged that a user having larger use records has more credit. The user is set with a longer settlement term and provided with service of reducing the number of settlement times.
In the example of the log data shown in FIG. 10 , a settlement term of Okuda is one day and that of Yamada is seven days according to the use records of March.
Similarly, the credit accepted of each user is determined (S 904 ).
It is judged that a user having larger use records has more credit. The user is set with a higher upper limit credit accepted and provided with service of reducing the number of settlement times.
In the example of the log data shown in FIG. 10 , an upper limit credit accepted of Okuda is 1,000 Yen and that of Yamada is 10,000 Yen according to the use records of March.
Next, in accordance with the data such as fee and settlement conditions of each user determined as above, the data such as fee and settlement conditions of each user in the service use record management table managed by the contract information unit 452 is updated (S 905 ).
FIG. 13 shows an example of the service use record management table updated in accordance with the use records of March.
When the data of each user is changed, this effect is notified to the user (S 906 ). A notifying means may be any means. An example of a display window on the user terminal 102 is shown in FIG. 14 .
The series of processes described above may be performed periodically or automatically when the amount of use records reaches a predetermined amount, by setting the operation manager 506 .
(Contracted Shop Royalty Update Process Depending Upon Use Records)
Next, means for providing service of reducing a royalty depending upon use records will be described, which means is used for expanding print service sites and promoting affiliation of print service shops.
FIG. 15 is a flow chart illustrating a process of updating a royalty of a contracted shop.
First, use records of the print service shop 101 are acquired from log data (S 1501 ). FIG. 16 shows an example of log data managed by the log information unit 454 . FIG. 16 shows use records as of March 2000, with a shop ID of a print service shop, a date of use, and an operation (use) fee. FIG. 17 shows a printer use record management table of each shop managed by the shop information unit 458 . Data in the table of FIG. 17 is the data before log data is acquired. Total records of the shop having a shop ID “0001” is 158,000 Yen and its royalty is 4.5%, and total records of the shop having a shop ID “0002” is 64,850 Yen and its royalty is 10.0%.
Next, a royalty of a contracted shop is determined from the acquired data and the contents of a contacted shop royalty reference table managed by the fee system unit (S 1502 ).
More discount service of a royalty is provided to a shop having larger operation records. FIG. 18 is an example of the contracted shop royalty reference table.
The table is used for determining a royalty basing upon total records counted from the service start. Instead, the table is preferably changed to a table suitable for service operation, for example, the table may be determined from records of each year.
Total records of the shop ID “0001” are 485,470 Yen and those of the shop ID “0002” are 136,950 Yen according to the log data shown in FIG. 16 . Therefore, the royalty is 4.5% for both the shops.
Next, in accordance with the royalty data of each shop determined by the above processes, the royalty data of each shop managed by the shop information unit 458 is updated (S 1503 ).
FIG. 19 shows an example of a printer use record management table updated in accordance with total records. Although the royalty of the shop ID “ 0001 ” remains 4.5%, the royalty of the shop ID “ 0002 ” lowers from 10.0% to 4.5%.
When the printer use record management table of each print service shop is updated, this effect is notified to the shop (S 1504 ). A notifying means may be any means. An example of a display window on the management terminal such as PC of a shop is shown in FIG. 20 .
The series of processes described above may be performed periodically or automatically when the amount of operation records of each shop reaches a predetermined amount, by setting the operation manager 454 .
(Shop Select Process by User)
Means for accessing the print service server 100 by a user to search a print service shop 101 and select the shop will be described.
FIG. 21 is a flow chart illustrating a shop select service process.
First, shop search conditions are designated (S 2101 ). The shop search conditions may be shop location information, shop current running status information, various discount information of each shop, or the like. The shop search conditions are not limited only to the above, but it is desired that the shop search conditions beneficial to a user are added depending upon the operation state.
Next, shop information matching the designated search conditions is acquired from the shop information registered in the print service server 100 (S 2102 ). The shop information is updated at proper timings.
FIG. 22 shows an example of a shop information table managed by the shop information unit 458 . By using the shop information table formed in accordance with the search conditions, designated shop information is derived.
In this table, shop location information, time service information and the like are managed as shop information. Other information beneficial to a user may be added. Shop information is dynamic information. Namely, this information is inquired from the server 100 to the shop 101 to notify the new information to a user.
Shop information is notified to the user (S 2103 ). An example of a display window on the user terminal 102 is shown in FIG. 23 . As shown in FIG. 24 , the location of a designated shop may be displayed on a map.
(Service Use Fee Computation Process)
Means for computing a service user fee of this embodiment will be described.
FIG. 25 is a flow chart illustrating a fee computation process.
First, a unit service fee of a service type used by a user is acquired from a service type standard unit fee table managed by the fee system unit 453 (S 2501 ).
The service type used by the user is acquired from log data. FIG. 26 shows an example of the structure of log data managed by the log information unit 454 . Since data of the service type used by a user, such as direct and remote, is registered as the log data, it is possible to judge the service type used by the user from this log data. The log information unit 454 constitutes a print service request type management means. The fee computer 408 for executing the following computation process constitutes a print service request type judging means and a print service use fee computing means.
An example of the service type standard unit fee table is shown in FIG. 27 .
The following description will be given by taking as an example a use fee of Okuda on Apr. 1, 2000 shown in FIG. 26 . Okuda printed a monochromatic copy of A 4 size in a direct service request mode. A standard fee per one A 4 sheet is 9 Yen as shown in FIG. 27 . The service type standard unit fee table corresponds to the user fee computation table and the fee system unit 453 constitutes a user fee computation table management means.
Next, a fee corresponding to a use amount (number of printed sheets or the like) is calculated from the acquired unit fee (S 2502 ).
In the example shown in FIG. 26 , Okuda printed out ten sheets so that 9×10=90 Yen.
Next, a discount rate managed by the contract information unit 452 for each user is acquired and a fee after discount is calculated from the obtained standard fee (S 2503 ).
From the service use record management table shown in FIG. 12 , the discount rate applied to Okuda is 1% so that 90×0.99=89.1 Yen.
Next, if a discount service at the shop can be applied, a predetermined discount rate is acquired from the shop information unit 458 to calculate again the fee (S 2504 ).
It is assumed in the above example that Okuda used the shop having the shop ID “0001”. Since the use time is the midnight, the discount rate is 30% as shown in the shop discount column of FIG. 22 . Therefore, the fee calculated again is 89.1 Yen×0.7=62.37 Yen which is rounded off to obtain a final fee of 63 Yen.
The discount rate in the shop discount column of the shop information shown in FIG. 22 varies with the operation status of the printer at each shop and with operation records at each shop.
The discounted fee at each shop is automatically claimed to the shop in another process.
The calculated data is managed as settlement data of each user and settlement is made in another process (S 2505 ).
The result of the above-described processes is registered in the log (S 2506 ). The registered log can be managed as service records.
In the above example, two types of service modes are prepared including a direct service request mode from the shop system and a remote service request via the print service server. In each mode, a standard fee and the like for a monochromatic print and a color print of each recording sheet size are set and managed. Instead, the unit service fee may be set and managed flexibly. The remote print fee is higher than the other service because it contains a communication fee.
(Settlement Related Process)
A settlement related process by the settlement maker 409 will be described.
FIG. 28 is a flow chart illustrating a settlement process.
When a settlement status confirmation request is received (S 2801 ), a settlement status of the user, particularly, presence/absence of arrears, unsettled amount and the like, managed by the settlement information unit 457 are acquired and notified to the requester (S 2802 ).
When a settlement process request is received (S 2803 ), settlement data is received and managed by the settlement information unit 457 (S 2804 ).
When a settlement process request of each user is received (S 2805 ), a settlement day, a credit accepted and the like of each user managed by the contract information unit 452 are checked and a process corresponding to a preregistered settlement means (credit card, bank transfer or the like) is executed (S 2806 ). This settlement process request is called periodically from the operation manager 406 .
When a settlement process request of each shop is received (S 2807 ), by using information managed by the shop information unit 458 , a settlement process based upon service records of each shop, a settlement process based upon royalty, a settlement process for user discount service and other processes are executed (S 2808 ). This request is periodically called from the operation manager 406 .
The processes to be executed by the print service system of the invention have been described above. The user charge management attribute update process, royalty update process of each contracted shop, service use fee computation process, settlement related process are not always required to be executed by computers interconnected by a network, but they may be executed manually by using a managing means such as books.
As described so far, according to the invention, a user is provided with a credit accepted so that it is convenient for the user to use the print service system.
Furthermore, as described above, according to the invention, a use fee is set in accordance with user use records and a user routinely using the system can use service at a low fee, and a print service shop can have routine users reliably. | A print service system capable of improving user settlement convenience by setting a charging system depending upon each service type and dynamically determining a fee depending upon the past use records of a user to provide services specific to each user. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to controlled deflection rolls of the type used in a papermaking machine press for forming a press nip with an opposed roll.
In a conventional press of the type used in a papermaking machine for dewatering a traveling web, two or more press rolls are pressed together with the requirement that they produce a substantially uniform line of nip load across the length of their contact.
The line load, also referred to as nip pressure, is generally measured in pounds per inch of width and will not be entirely uniform with plain rolls due to differences in the deflection of the rolls under different applied loads. Plain press rolls can be contoured or crowned to compensate for the deflection at a specific load, but the resulting nip pressure will not be uniform along the nip for other loadings.
A solution to this problem for obtaining uniform nip pressure at varying nip loads is the use of controlled deflection rolls. Sometimes, this type of roll is referred to as a controlled crown, or CC, roll. In these rolls, the nip pressure profile can be adjusted by increasing or decreasing the pressure applied to the shell from inside the roll. The structure of such a roll involves a roll shell supported on a central shaft extending co-axially therethrough with a fluid-controllable, load-supporting means between the shaft and the roll shell opposite the nip line. Various nip-loading devices have been employed for loading the nip by transferring the forces to the inner surface of the roll shell from the shaft. These arrangements provide for loading the nip and, in certain circumstances, for controlling the load along the length of the nip so that an adjustable crown can be obtained, that is, either a uniform nip or a controlled nip. In one form, the support pressure applied to the nip is accomplished by an oil lubricated shoe wherein the pressure of the oil and the force on the shoe opposite the nip can be controlled or adjusted. With this type of construction, the shell is typically formed of heavy cast metal and machined to the required dimensions and surface smoothness inside and out.
The amount of mass which makes up the complete controlled deflection roll, including the cast roll shell, shoe and shaft plus the loading arms, influences nip vibration. In some constructions, the roll shell is covered with a synthetic cover, and these vibrations will cause corrugations in the roll cover, as well as in the felt which is passed through the nip with the web. Most corrugation and roll bouncing problems are related to the recovery time of the roll cover elastomer.
One partial solution to the problem is to mount anti-friction bearings, which support the roll shell, to a carrier ring which is slidably or pivotally mounted to the center shaft. The nip loading shoe is then used to raise the roll shell into contact with the mating roll. Such a construction reduces the total vibrating weight, but it also lowers the natural frequency of the roll, which is undesirable.
The nip-loading shoe has been used to raise the shell into contact with the mating roll and, in this arrangement, the center shaft and mounting do not participate in nip vibrations because they are not mechanically linked with the roll shell when the roll shell is moved radially in the direction of the nip. This reduces the inertial mass load on the press nip. Because the bearings are mounted on a movable carrier, or bearing ring, and are, therefore, not directly supported on the center shaft, opposing end shoes must be added to reduce the bending moment needed to change the contour of the nip profile. These counter-shoes add additional rotational resistance to the shell. Because the shoes are located closer to the roll center than the rotational bearings in a conventional controlled crown roll, the bending moment is reduced, thus limiting the crown control. Further, the massive shell is still able to cause some damage to the felts and to roll covers due to its own mass, which affects nip loads during nip vibrations.
It is accordingly an object of the invention to provide an improved controlled crown roll structure which avoids disadvantages of structures heretofore available.
A further object of the invention is to provide an improved roll shell for a controlled crown roll construction wherein the mass is greatly reduced to reduce the problems of nip vibrations and other consequent disadvantages of operation.
A still further object of the invention is to provide an improved controlled crown roll with a unique shell construction wherein the shell weight will be substantially less than with conventional cast metal shells and wherein the shell thickness is reduced and cross-machine stiffness reduced.
FEATURES OF THE INVENTION
In accordance with the principles of the invention, a controlled crown roll is provided with a center shaft and supporting liquid pressure crown control supports, such as hydraulically actuated shoes. The roll shell is formed of a fiber-reinforced resin. The shell, in the construction provided, will have about 20% of the weight of a conventional cast metal shell of the same dimensions and can be less than about 10% of the weight of a conventional cast metal roll shell if the shell thickness is reduced. The reduced thickness is possible because the shell stresses are predominantly compressive stresses. The reduced mass will greatly reduce the potential for the press nip to damage felts and roll covers.
The roll shell is comprised of inner, intermediate and outer layers. Each layer is formed of a composite of a matrix and fibers. The matrix is a chemically inert, glue-like structure which holds the fibers together in a desired location and orientation, and transfers the load from fiber to fiber. The matrix also protects the fibers from damage due to elevated temperatures and humidity.
Regarding the three layers, the inner layer is comprised of high abrasion resistant fiber, preferably randomly orientated, and a high temperature resistant, fluid impermeable matrix. The inner surface of the inner layer is comprised mostly, or entirely, of matrix so as to better protect and support the fibers from loss of lubrication, liquids, such as oil contaminants, stress and shear.
The intermediate layer has its fibers oriented to be aligned substantially circumferentially to provide maximum hoop strength.
The outer layer is a composite comprised of a matrix in which fibers are randomly oriented. Examples of the preferred matrix, particularly for the outer layer, are epoxy, polyester, phenolics, polyamids, and bisnalaimides. Preferred fibers for the outer layer include aramids, ceramic, glass, graphite, para-aramids and meta-aramids.
The matrix is selected for high impact strength and fracture resistance. This guards against the potential of the roll's surface being either dented or shattered, both of which would be deleterious to the roll's operation in a papermaking machine.
Examples of preferred, high strength and modulus, high abrasion resistance fiber include aramids, ceramic, glass, graphite, para- and meta-aramids. Examples of preferred impermeable, high temperature matrices include toughened epoxies, urethane, thermoplastic, PEEK (Poly Ether Ether Ketone), PPS (Poly Phenylene Sulfide) and nylon, for example. Such high strength and abrasion resistant fibers and high temperature, impermeable matrices are preferred for use in the inner layer where sliding friction with the hydraulically actuated shoes, and exposure to hydraulic oil contaminants, would be expected to be encountered during operation.
Other objects, advantages and features will become more apparent, as will equivalent structures which are intended to be covered herein, with the teaching of the principles of the invention in connection with the disclosure of the preferred embodiments thereof in the specification, claims and drawings, in which:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side-elevational view, partially in section,. of a controlled crown roll with a mating roll forming a press nip therebetween;
FIG. 2 is a sectional view taken substantially along line II--II of FIG. 1;
FIG. 3 is a sectional view taken substantially along line III--III of FIG. 1; and
FIG. 4 is an enlarged fragmentary sectional view along the line IV--IV of FIG. 3 showing the construction of the roll shell.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in FIGS. 1 and 2, a controlled deflection roll press assembly includes an upper, mating press roll 11 which is rotatably mounted on a shaft supported in bearings 12 and 13.
A lower, controlled deflection roll 10 forms a nip with the upper press roll. The position of the rolls may in some instances be reversed with the controlled deflection roll 10 being above the mating roll 11.
The controlled deflection roll includes a rotatable shell 14 with a supporting shaft 15 extending axially therethrough. The supporting shaft is non-rotatable but is supported in framework 19,20 by spherical bushings 17,18 to permit bending of the roll 10, and deflection of the support shaft, as it carries the load of applying forces to the nip N between press rolls 10,11.
The nip load is controlled by fluid pressure control means, such as pistons 16 between the roll shell and the shaft 15, which exert an upward force to control the forces in the nip. To an extent, the contour of the nip can also be controlled by this means. At the ends of the roll shell are bearings, shown at 21 at one end with a similar bearing at the opposite end. These bearings maintain the ends of the roll shell in alignment with the shaft and with the nip N.
To ensure that the ends of the roll are maintained in alignment with both the nip and the support center shaft, the bearings at each end of the roll are mounted to a bearing ring 24 which, in turn, is pivotally attached to the center shaft 15 with a pivot pin 9 which is mounted in a pillow block 25. In FIG. 2, the bearing ring is shown broken away for clarity. Each side of the center shaft 15 has a flat surface 22,23, which surfaces are parallel, to facilitate mounting the pillow block 25 at each end of the shaft. On the side of the shaft at each end of the shaft opposite the pillow blocks is a U-shaped guide 25' which engages the bearing ring 24 to guide it in its pivoting path of travel and to provide axial thrust support.
While various forms of nip loading support means may be provided for loading the nip, that is applying a nip loading force to the inner surface of the roll shell 14, one form is shown by a series of hydraulically actuated, hydrostatic shoes 32 arranged at spaced intervals longitudinally on the support shaft in a cross-machine direction and supported on the shaft 15. The shoes may be uniformly loaded or differentially loaded, depending upon the nip contour loading desired.
Nip loading hydraulic pressure is provided by a hydraulic pump, not shown, which supplies hydraulic fluid, such as oil, through a single center core passage 26, FIG. 3, in the shaft 15, or alternatively, through a series of hydraulic passages, not shown. The center passage 26 has vertically extending individual riser passages 27 which lead to a cylinder chamber 28 beneath the base of each of the pistons 32. These pistons 32 are sometimes referred to as shoes in the papermaking industry. The hydraulic fluid pressure in the chamber 28 urges the shoe 32 upwardly to support the load and, to ensure constant lubrication and hydrostatic fluid support, the hydraulic fluid, under pressure, is channeled upwardly through passages 29, sometimes called capillary tubes, in the piston into pockets 30,31 in the shoe 32 surface facing the inner surface of the roll shell 14.
In some instances, counter-load shoes 34 may be provided. One of the functions of these shoes is to raise the roll shell when the shell is mounted in an inverted position, that is, when the controlled deflection roll is above the plain roll. Other passages 33 lead from the center core passages 26 to a chamber 28a beneath the piston 34a and passages 35 through the piston open into lubrication pockets 36,37 in the face of the shoe 34 facing the inner surface of the roll shell. The fluid transmitted to the pistons 34a is controllable so that it can be used to raise the roll shell and, if used during operation, the pressure is controllable so that the nip loading shoes 32 can perform their function of loading the nip and provide an appropriate nip pressure profile.
The controlled deflection roll shell 14, as shown in FIGS. 3 and 4, is constructed of a lightweight matrix and fiber composite, preferably multi-layered with concentric annular layers. The roll shell is comprised of a fiber-reinforced matrix, such as epoxy, for example, which will have a total weight of only 20% of the weight of a conventional controlled deflection roll shell of the same thickness, but made of steel. Actually, the weight can be less than 10% of the weight of a normal steel shell if the shell thickness is reduced to a minimum required for mechanical stability. The reduced shell thickness is possible because the shell stresses are predominantly compressive stresses and the composite shell can readily tolerate compressive stresses. The reduced mass will greatly reduce the potential for press nip damage to the felts and roll cover.
The shell is manufactured with reinforcing fibers 40 in an intermediate layer, and these reinforcing embedded fibers are oriented in the circumferential direction, as shown in FIG. 4. This does not add to the cross-machine direction bending stiffness of the shell, but it still increases the hoop stiffness of the shell. This allows the shell to bend more easily and might eliminate the need for counter-acting shoe loadings near the ends of the roll shell. The high hoop stiffness maintains an essentially cylindrical roll shell shape.
Another advantage of this shell construction is the ease of balancing. The shell can be manufactured on a precision smooth mandrel. This eliminates the need to bore the shell. Further, a lower mass results in lower potential imbalance forces.
The composite shell has a naturally higher vibration dampening coefficient. Proper selection of matrices and fibers will provide a chemically inert, wear-resistant, impact-resistant, impermeable shell. Due to inherent structural properties of the matrices (e.g. the ability to transfer stresses between fibers and to provide abrasion resistance), and the fibers (e.g. the ability to provide tensile strength, and to distribute load) in the composites, fatigue failures would not be catastrophic. Fatigue failures will manifest themselves in typically slowly progressive failures.
The composite roll shell has an inner layer 39 of a high abrasion-resistant fiber and a high-temperature, impermeable composite matrix. This inner layer construction is used to minimize shell damage due to oil contaminants or temporary loss of lubrication. Preferred matrix materials for construction of the inner layer are toughened epoxies, urethane, thermoplastic, PEEK, PPS and nylon. Preferred fibers for the inner layer are aramids, ceramic, glass, graphite, para- and meta-aramids. It is preferred to have the inner surface of the inner layer comprised of a matrix material with no fiber material, or very little fiber material exposed.
The center core layer 40 (i.e. the intermediate layer) of the composite shell is comprised of a high strength fiber. This fiber is wound on the inner surface layer with the fibers predominantly oriented in a circumferential direction. This construction develops a high shell stiffness to prevent the shell from distorting out of the circular shape while providing low resistance to roll bending so that the crown or deflection of the roll shell can be easily controlled. Preferred fibers for the center core, or intermediate, layer include aramids, ceramic, glass, graphite, para-aramids and meta-aramids. Preferred matrices for the center core, or intermediate, layer include toughened epoxies, urethane, thermoplastic, PEEK (Poly Ether Ether Ketone), PPS (Poly Phenylene Sulfide) and nylon.
The outer layer 38 of the composite shell comprises a composite of fibers and matrix which provide impact resistance, wear resistance, and a surface which can be routinely ground to maintain the outer surface crown profile. Preferred matrices for the outer layer include toughened epoxies, urethane, thermoplastic, PEEK (Poly Ether Ether Ketone), PPS (Poly Phenylene Sulfide) and nylon. Other matrix materials which are useful and preferred for use in the outer layer are epoxies, polyesters, phenolics, polyamids and bisnalaimides. Preferred fibers for the outer layer include aramids, ceramic, glass, graphite, para-aramids and meta-aramids.
In operation, the nip is closed and a web to be pressed is threaded through the nip N. The shoes are loaded with oil pressure to maintain the desired nip load. The nip loading shoes can be divided or further segmented or controlled as to hydraulic fluid pressure supplied thereto in the cross-machine direction to allow adjustability to the nip pressure profile. The roll shell is rotated at a relatively high speed to accommodate present high speed papermaking machines when the nip is utilized in a dewatering section of a paper machine. The relatively lightweight roll shell is capable of a long operating life and has a relatively low bending stiffness in the cross-machine direction. Because the layers of the shell are chosen to provide a high abrasion resistant composite on the inner surface which also has high temperature resistance, the shell damage due to oil contaminants or temporary loss of lubrication is minimized. With the high hoop strength of the shell, the shell is capable of a long operating life providing an improved function, as well as obtaining a shell which is manufactured without the necessity of providing huge molding facilities and huge machining facilities, such as are necessary with a cast steel shell. Where the steel shell must have an exterior coating of rubber or high release material, the resin which is chosen for the outer surface of the shell can have these features without an additional coating layer, or alternatively, be selected for improved bonding to said coating or material.
Thus, it will be seen there has been provided an improved controlled deflection roll which meets the objectives and advantages above set forth. | A controlled deflection roll for forming a press with an opposed roll including an elongate tubular roll shell, an elongate support shaft extending longitudinally through the roll shell, and a fluid operated controllable load support means between the shaft and the shell, such as a piston with an open pressure hydrostatic oil interface facing the shell. The roll shell is constructed of a fabricated fiber reinforced matrix, and is comprised of a plurality of annular layers of fiber and matrix composite, so that the shell is of relatively light weight and has a reduced cross-machine bending stiffness. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to sewing machines that form stitching patterns on a fabric web by the cooperative motion of needles and shuttles.
A sewing machine such as a quilting machine has a needle plate and a plurality of needles, which are arranged above the needle plate. The needles are reciprocated vertically to pierce a fabric web and feed upper threads. A shuttle is arranged in correspondence with each needle below the needle plate. Each shuttle is reciprocated transversely relative to the associated needle. A bobbin wound with a lower thread is housed in each shuttle. The cooperative reciprocation of the needles and the shuttles forms stitching patterns on the fabric web with the upper and lower threads.
In a typical quilting machine, a lower thread having a predetermined length is wound on a bobbin. When all of the lower thread becomes used during the sewing operation, the shuttle accommodating the empty bobbin is manually removed from its sewing position and replaced with a shuttle accommodating a full bobbin. The burdensome replacement of the shuttles degrades the sewing efficiency.
The manual replacement of shuttles is especially inefficient when using a quilting machine that employs a large number of shuttles. The manual replacement of shuttles in a quilting machine consumes a large amount of time.
SUMMARY OF THE INVENTION
Accordingly, it is an objective of the present invention to provide a sewing machine that enhances sewing efficiency.
To achieve the above objective, an improved sewing machines is proposed. The sewing machine has needles reciprocally movable in a first direction through a fabric web and shuttles reciprocally movable in a second direction perpendicular to the first direction. The used shuttles accommodating an empty bobbin is replaced with the new shuttle accommodating a full bobbin. The needles and the shuttles cooperate to form stitch patterns on the fabric web. A device is provided for the automatic replacement of the used shuttle with the new shuttle.
Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principals of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings:
FIG. 1 is a side view showing a sewing machine according to the present invention;
FIG. 2 is an enlarged side view showing a sewing device employed in the sewing machine of FIG. 1;
FIG. 3 is an enlarged cross-sectional view showing the sewing device;
FIG. 4 is a schematic perspective view showing the sewing device;
FIG. 5 is an enlarged side view showing a shuttle exchanging device employed in the sewing machine;
FIG. 6 is a side view showing the operation of the shuttle exchanging device;
FIG. 7 is a side view showing an operating procedure taken by the shuttle exchanging device;
FIG. 8 is a side view showing the operational procedure taken by the shuttle exchanging device subsequent to the procedure shown in FIG. 7;
FIG. 9 is a side view showing the operational procedure taken by the shuttle exchanging device subsequent to the procedure shown in FIG. 8;
FIG. 10 is a side view showing the operational procedure taken by the shuttle exchanging device subsequent to the procedure shown in FIG. 9;
FIG. 11 is a side view showing the operational procedure taken by the shuttle exchanging device subsequent to the procedure shown in FIG. 10, and
FIG. 12 is a side view showing the operational procedure taken by the shuttle exchanging device subsequent to the procedure shown in FIG. 11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A quilting machine according to the present invention will now be described with reference to FIGS. 1-12.
A quilting machine includes a sewing device 21 and a shuttle exchanging device 22, as shown in FIGS. 1 and 2. The sewing device 21 has a main frame 23 on which a needle plate 24 is arranged. Layered fabric webs 25 are transferred along the needle plate 24. Two rows of equally spaced needles 26 are arranged above the needle plate 24. Each needle 26 is reciprocated vertically to pierce the fabric web 25 held on the needle plate 24. Each needle has an eye 26a through which an upper thread is threaded. The upper thread is fed from a thread supply source (not shown).
As shown in FIGS. 1, 2, and 4, a movable platform 27 is arranged under the needle plate 24. The platform 27 is guided by guide rods 28 to move reciprocally in a direction perpendicular to the axes of the needles 26 (the direction parallel with the plane of FIG. 2). Pairs of guide rails 27a are arranged on the platform 27. A shuttle holder 29 is movably held on each pair of guide rails 27a and guided along a guide wall 53. A shuttle carrier 30 is provided on each shuttle holder 29 for each needle 26. A shuttle 31 is detachably held in each carrier 30 for each needle 26. Each shuttle 31 corresponds to one of the needles 26. A bobbin (not shown) wound with a predetermined length of the lower thread is housed in each shuttle 31.
A drive shaft 32 is rotatably supported by the main frame 23 under the movable platform 27. A lever 33 is fixed to the drive shaft 32. The lever 33 has a distal end on which a roller 35 is rotatably supported. The platform 27 includes an engaging portion 34, which engages the roller 35. When the lever 33 moves between the position shown by the solid lines and the position shown by the broken lines in FIGS. 1 and 2, the platform 27, the shuttle holders 29, and the shuttles 31 are moved in a direction perpendicular to the needles 26. The cooperative motion of the needles 26 and the shuttles 31 forms stitching patterns on the fabric web 25.
As shown in FIGS. 2 and 4, a pair of fixed stoppers 36 are fixed to the front end of the platform 27 in correspondence with each shuttle holder 29. When each shuttle holder 29 is moved away from the shuttle exchanging device 22 along the platform 27, the associated fixed stoppers 36 engages the front end 29a of the shuttle holder 29 and restricts further advancement of the shuttle holder 29.
A rotary shaft 37 is supported at the rear end of the platform 27. A lever 38 is fitted on each end of the rotary shaft 37. A movable stopper 39 is pivotally supported on the rotary shaft 37 in correspondence with each fixed stopper 36. A bracket 40 is provided for each movable stopper 39 and fixed to the rotary shaft 37. Each bracket 40 supports a roller 41. A pair of springs 42 are intervened between each movable stopper 39 and the associated bracket 40 to urge the movable stopper 39 toward the corresponding fixed stopper 36. To facilitate understanding, two brackets 40 are shown at different positions in FIG. 4. However, the brackets 40 are actually aligned with each other on the rotary shaft 37.
A locking cylinder 43 is provided for each bracket 40 on the main frame 23. Each cylinder 43 has a piston rod on which an actuator 44 is attached. The actuator 44 is engaged with the associated roller 41. When each cylinder 43 extends its piston rod with the shuttle holders 29 held on the platform 27, the associated movable stoppers 39 are moved to a position shown by the solid lines in FIG. 2. The movable stoppers 39 are pressed against the rear end 29b of the associated shuttle holders 29 by the force of springs 42 to prevent the shuttle holder 29 from moving toward the shuttle exchanging device 22.
An unlocking cylinder 45 is provided for each lever 38 on the main frame 23. Each cylinder 45 has a piston rod on which an actuator 46 is attached. The actuator 46 engages the lever 38. When the cylinder 45 extends its piston rod, the lever 38 is pivoted about the rotary shaft 37 such that the associated movable stopper 39 and bracket 40 are moved to the position shown by the dashed lines in FIG. 2. This separates the movable stopper 39 from the rear end 29b of the shuttle holder 29 and permits the movement of the shuttle holder 29 toward the shuttle exchanging device 22.
As shown in FIGS. 3 and 4, a plurality of support blocks 48 are fixed to the platform 27. A bore 47a and a bore 47b are provided for each support block 48. Each set of bores 47a, 47b extends radially through the rotary shaft 37 in different directions at the same location. A movable frame 49 is movably supported by the support block 48 by means of guide rods 54 and guide bores 55. A pin 50, which engages and disengages the bore 47a or the bore 47b, extends through the middle of the movable frame 49.
A pair of springs 51 are arranged between each support block 48 and the associated movable frame to urge the movable frame 49 such that the pin 50 is inserted through the bore 47a or the bore 47b. A cylinder 52 is provided for each movable frame 49 on the platform 27 to disengage the pin 50 from the bore 47a or 47b. Each cylinder 52 has a piston rod 52a that engages the associated frame 49.
During normal sewing operation, the piston rod 52a of each cylinder 52 is retracted as shown by the solid line in FIG. 3. In this state, the associated pin 50 is moved into one of bores 47a, 47b by the force of the springs 51 to lock the rotary shaft 37. This restricts the rotation of the rotary shaft 37 and prevents the movable stoppers 39 from being moved to the position shown by the dashed lines in FIG. 2.
When all of or nearly all of thread wound on each bobbin is used, the associated shuttle 31 must be replaced with a new shuttle 31. In such case, the cylinders 52 project their piston rods 52a to move the movable frames 49 against the force of the springs 51. This moves the pins 50 out of the bore 47a or the bore 47b and unlocks the rotary shaft 37. As a result, the movable stoppers 39 can be pivoted to the position shown by the dashed lines in FIG. 2.
The structure of the shuttle exchanging device 22 will now be described with reference to FIGS. 1, 5, 6, and 7.
The shuttle exchanging device 22 is located adjacent to the sewing device 21 and employed to replace shuttles 31 holding empty bobbins with shuttles 31 holding full bobbins. The shuttle exchanging device 22 includes a frame 56, which is secured to the rear portion of the sewing device 21, a transfer mechanism 57 for transferring the shuttle holders 29, a discharge mechanism 58 for discharging the shuttles 31 holding empty bobbins, and a supply mechanism 59 for supplying shuttles 31 holding full bobbins.
The transfer mechanism 57 transfers shuttle holders 29 supporting shuttles 31 between a sewing position, which is located in correspondence with the sewing device 21, and a shuttle exchange position, which is separated rearward from the sewing device 21. The discharge mechanism 58 discharges shuttles 31 holding empty bobbins from the shuttle holders 29 at the shuttle exchange position. The supply mechanism 59 supplies shuttles 31 holding full bobbins to the shuttle holders 29 at the shuttle exchange position.
A pivotal platform 61 is pivotally supported by a rotary shaft 62 for each shuttle holder 29 in the discharge mechanism 58. A pair of guide rails 63 extend along the pivotal platform 61. A transfer plate 64 is movably supported between the guide rails 63. A pair of hooks 65 are pivotally supported by a pivot pin 66 on the transfer plate 64. Each hook 65 engages a key 67 located at the rear end of the shuttle holder 29.
A rodless transfer cylinder 68 having a piston connected to the transfer plate 64 is arranged under the pivotal platform 61, as viewed in FIG. 5. The rodless transfer cylinder 68 drives the transfer plate 64 such that each hook 65 is moved between the sewing position shown in FIG. 8 and the shuttle exchange position shown in FIG. 7.
A hooking cylinder 69 is arranged on the transfer plate 64. The cylinder 69 has a piston rod that is pivotally connected with the pivot pin 66 by a connecting lever 70.
When the hooks 65 and the transfer plate 64 are located at the sewing position shown in FIG. 8, projection of the piston rod from the cylinder 69 engages the hooks 65 with the key 67 by means of the lever 70 and the pivot pin 66. In the same state, the retraction of the piston rod into the cylinder 69 pivots and separates the hooks 65 from the key 67.
Furthermore, the hooks 65 engaged with the key 67 and the transfer plate 64 are moved from the sewing position to the shuttle exchange position by the cylinder 68. This causes the shuttle holders 29 supporting shuttles 31 to move from the sewing position on the platform 27 to the shuttle exchange position on the platform 61, as viewed in FIGS. 5 and 9.
As shown in FIGS. 5 and 6, the platform 61 includes a stopper cylinder 71. When the shuttle holders 29 are located at the shuttle exchange position on the platform 61, the stopper cylinder 71 is projected to engage part of the shuttle holders 29. As a result, the shuttle holders 29 are locked to the platform 61.
The discharge mechanism 58 includes a pivoting cylinder 72, which is pivotally supported about a pivot pin 73 on the frame 56. The pivoting cylinder 72 has a piston rod, which is connected to the rear end of the platform 61. When the shuttle holders 29 are located at the shuttle exchange position on the platform 61, projection of the piston rod from the cylinder 72 pivots the platform 61 from a horizontal position to a vertical position, as viewed in FIGS. 6 and 10. Shuttles 31 holding empty bobbins fall off the shuttle holders 29 when the platform 61 is located at the vertical position.
As shown in FIG. 10, air nozzles 74 are arranged under the platform 61 in correspondence with the shuttles 31 held on the shuttle holders 29. When the platform 61 supporting the shuttle holders 29 is pivoted to the vertical position, compressed air is blasted toward the shuttles 31 from the air nozzles 74. This aids the removal of the shuttles 31 from the shuttle holders 29.
As shown in FIGS. 1, 5, 6, and 10, a shuttle chute 75, which extends obliquely, is arranged at the lower portion of the frame 56. A retriever 76 is defined at the lowest portion of the shuttle chute 75 to receive the shuttles 31 that fall off the shuttle holders 29 and slide down the chute 75.
As shown in FIGS. 1, 5, and 11, the supply mechanism 59 includes a plurality of tubular shuttle retainers 77 that are held obliquely by a feeder 78 located above the frame 56. When the shuttle holders 29 are moved to the shuttle exchange position, the tubular shuttle retainers 77 are arranged in correspondence with the shuttle carriers 30. Each shuttle retainer 77 has a lid 79 that is pivotally supported about a pivot pin 80 at the lowest end of the shuttle retainer 77. The lid 79 selectively opens and closes lower ends of the shuttle retainers 77. The feeder 78 includes a feeder cylinder 81. The cylinder 81 has a piston rod that is connected to the lids 79 by connecting levers 82.
As shown in FIGS. 5 and 7, the piston rod of the cylinder 81 is normally retracted. Thus, the lower ends of the shuttle retainers 77 are normally closed by the lids 79. A shuttle 31 holding a full bobbin is retained in each shuttle retainer 77 above the associated shuttle carrier 30.
After shuttles 31 holding empty bobbins are discharged from the shuttle holders 29 by the shuttle discharge mechanism 58, the piston rod of the cylinder 81 is projected to pivot each lid 79 and open the lower end of the associated shuttle retainers 77 by means of the connecting lever 82, as shown in FIG. 11. This causes the retained shuttle 31, which holds a full bobbin, to fall onto the associated shuttle carrier 30.
The operation of the sewing machine will now be described with reference to FIGS. 7-12.
As shown in FIGS. 1, 2, and 7, when the sewing machine performs the sewing operation, the shuttle holders 29 supporting shuttles 31 are located at the sewing position on the movable platform 27 of the sewing device 21. The front end 29a of each shuttle holder 29 is engaged with the associated fixed stoppers 36 and the rear end 29b of each holder 29 is engaged with the associated movable stoppers 39. Thus, each shuttle holder 29 is fixed at its predetermined position on the movable platform 27.
In this state, each needle 26 is reciprocated vertically to pierce the fabric web 25. Simultaneously, the lever 33 is reciprocally pivoted by the drive shaft 32 between the positions shown by the solid lines and the dashed lines in FIGS. 1 and 2. This moves the shuttle holders 29, which is supported on the movable platform 27, back and forth in a direction perpendicular to the axes of the needles 26. The cooperative motion of the needle 26 and the associated shuttle 31 forms stitching patterns on the fabric web 25 with the upper thread supplied to the needle 26 and the lower thread from the bobbin held in the shuttle 31.
When the bobbins become empty or nearly empty, the shuttles 31 holding such bobbins are replaced by shuttles 31 holding full bobbins. To replace the shuttles 31, the piston rod 52a of each cylinder 52 is projected from the position shown in FIG. 3. This moves the associated movable frame 49 against the force of the springs 51. As a result, the pin 50 is disengaged from the bore 47a thereby unlocking the rotary shaft 37.
The actuator 46 of each unlocking cylinder 45 is projected from the position to rotate the rotary shaft 37 with the associated lever 38. This pivots the movable stoppers 39 and the brackets 40 from the position shown by the solid lines in FIG. 2 to the position shown by the dashed lines in FIG. 2. As a result, each movable stopper 39 is moved away from the rear end 29b of the associated shuttle holder 29, thus freeing the rear side of the shuttle holder. The piston rod 52a of each cylinder 52 is then retracted to insert the pin 50 into the other bore 47b using the force of the springs 51. This locks the rotary shaft 37. Afterward, the rodless transfer cylinder 68 of the transfer mechanism 57 employed by the shuttle exchanging device 22 moves the transfer plate 64 toward the sewing device 21 along the guide rail 63 of the pivotal platform 61. This moves the hooks 65 from the exchange position shown in FIG. 7 to the sewing position shown in FIG. 8. In this state, the piston rod of the hooking cylinder 69 is projected to pivot the hooks 65 counterclockwise by means of the connecting lever 70 and the pivot pin 66. This engages the hooks 65 to the key 67 located at the rear end of the associated shuttle holder 29.
Subsequently, the rodless transfer cylinder 68 moves the transfer plate 64 away from the sewing device 21 and returns the hooks 65 to the exchange position. As shown in FIG. 9, this moves the shuttle holder 29 supporting the shuttles 31 holding empty bobbins from the sewing position on the movable platform 27 to the shuttle exchange position on the pivotal platform 61 of the shuttle exchanging device 22. In this state, the stopper cylinder 71 fixes the shuttle holder 29 to the pivotal platform 61.
The piston rod of the pivoting cylinder 72 of the discharge mechanism 58 is projected to pivot the pivotal platform 61 and the shuttle holder 29 from the horizontal position shown in FIG. 9 to the vertical position shown in FIG. 10. This causes the shuttles 31 holding empty bobbins to fall off the shuttle holder 29. Compressed air is also blasted against each shuttle 31 from the air nozzles 74 to aid the removal of the shuttles 31 from the shuttle holder 29. The shuttles 31 then slide down the chute 75 and are retrieved by the shuttle retriever 76.
The piston rod of the pivoting cylinder 72 is then retracted to return the pivotal platform 61 and the shuttle holder 29 to the original horizontal position as shown in FIG. 11. In this state, the piston rod of the cylinder 81 of the supply mechanism 59 is projected to pivot each lid 79 and open the lower end of each shuttle retainer 77. This places shuttles 31 holding full bobbins onto the associated shuttle carrier 30.
After feeding the shuttles 31, the stopper cylinder 71 frees the shuttle holder 29. The rodless transfer cylinder 68 then moves the transfer plate 64 to the sewing device 21. The hooks 65 are pivoted from the shuttle exchange position shown in FIG. 11 to the sewing position shown in FIG. 12. Consequently, the shuttle holder 29, which supports shuttles 31 holding full bobbins, is transferred from the shuttle exchange position located on the pivotal platform 61 of the shuttle exchanging device 22 to the sewing position located on the movable platform 27 of the sewing device 21. The piston rod of the hooking cylinder 69 is then retracted to remove the hooks 65 from the key 67 at the rear end of the associated shuttle holder 29.
Subsequently, the pin 50 is removed from the bore 47b by the cylinder 52 to unlock the rotary shaft 37. In this state, the locking cylinders 43 pivot the movable stoppers 39 to the position shown by the solid lines in FIG. 2 by means of the bracket 40. The movable stoppers 39 are pressed against the rear end 29b of the shuttle holder 29 by the force of the springs 42. This restricts movement of the rear end of the shuttle holder 29. In this state, the fixed stoppers 36 are engaged with the front end 29a of the shuttle holder 29 thus restricting movement of the front end of the shuttle holder 29. Each cylinder 52 then retracts its piston rod to move the associated movable frame 49 with the force of the springs 51 so that the pin 50 is inserted into the bore 47a. This locks the rotary shaft 37.
The cooperative motion of the transfer mechanism 57 of the shuttle exchanging device 22, the shuttle discharge mechanism 58, and the supply mechanism 59 automatically replaces shuttles 31 holding empty bobbins with the shuttles 31 holding full bobbins. Therefore, replacement of the shuttles 31 is performed within a short period of time. Accordingly, the sewing machine quickly commences the sewing operation.
The preferred and illustrated embodiment obtains the following advantages.
The shuttle exchanging device 22 is employed to replace shuttles 31 holding lower thread bobbins. Thus, when the bobbins become empty or nearly empty, the bobbins are automatically replaced with shuttles 31 holding full bobbins. This enhances the sewing efficiency.
The shuttle exchanging device 22 includes the transfer mechanism 57, which transfers the shuttle holders 29 between the sewing position and the shuttle exchange position. The discharge mechanism 58 discharges shuttles 31 holding empty bobbins from the shuttle holders 29 at the discharge position. The shuttle supply mechanism 59 supplies shuttles 31 holding full bobbins to the shuttle holders 29 at the shuttle exchange position. Accordingly, the shuttle exchanging device 22, which structure is simple, guarantees the replacement of shuttles 31 holding empty bobbins with shuttles 31 holding full bobbins.
The shuttle transfer mechanism 57 employs the hooks 65, which engage the key 67 of the associated shuttle holder 29. The rodless transfer cylinder 68 moves the hooks 65 between the sewing position and the shuttle exchange position. Accordingly, the transfer mechanism 57 moves the shuttle holders 29 between the sewing position and the shuttle exchange position with a simple structure.
The discharge mechanism 58 employs the pivotal platform 61, which supports the shuttle holders 29 at the shuttle exchange position, and the pivoting cylinder 72, which pivots the platform 61 between the horizontal position and the vertical position. Accordingly, the discharge mechanism 58 discharges shuttles 31 holding empty bobbins from the shuttle holders 29 with a simple structure.
The supply mechanism 59 employs the shuttle retainers 77, which retain shuttles 31 holding full bobbins above the shuttle holders 29 at the shuttle exchange position, and the cylinder 81, which removes shuttles 31 from the shuttle retainers 77 onto the shuttle holders 29. This structure guarantees the supply of shuttles 31 holding full bobbins to the shuttle holders 29.
It should be apparent to those skilled in the art that the present invention may be embodied in may other specific forms without departing from the spirit of scope of the invention. Particularly, it should be understood that the present invention may be embodied in the following forms.
A conveyor may be connected to the shuttle retriever 76 in the discharge mechanism 58 so that shuttles 31 holding empty bobbins may automatically be transferred to a designated location.
A shuttle replenishing mechanism may be arranged above the shuttle retainers 77 in the supply mechanism 59 to automatically replenish the retainers 77.
Therefore, the present examples and embodiments are to be considered as illustrative and not restrictive and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalence of the appended claims. | A sewing machine has needles reciprocally movable in a first direction through a fabric web and shuttles reciprocally movable in a second direction perpendicular to the first direction. The used shuttles accommodating an empty bobbin is replaced with the new shuttle accommodating a full bobbin. The needles and the shuttles cooperate to form stitch patterns on the fabric web. A device is provided for the automatic replacement of the used shuttle with the new shuttle. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention:
[0002] Embodiments of the invention relate to pump-type dispensers and more particularly to lock-down features for such dispensers, including lock-down features involving a yieldable interference fit which requires a greater torque to start rotation from a fully locked position, than to rotate the dispenser to an unlocked, use position.
[0003] 2. State of the Art:
[0004] Lock-down and lock-up features are known for various types of dispensers. The lock features provide some resistance against children opening the dispensers, but they also prevent leaking during shipping from the manufacturer to the consumer.
[0005] When dispensers are shipped to retail stores, the shipments are often in case lots where many units are packaged inside heavy corrugated cartons. Such cartons help protect the product during shipment. If the lock-down (or lock-up) feature involves a rotation of the pump head, such rotation might be generally avoided when shipping is within heavy packaging. With the advent of online shopping (sometimes known as “e-commerce”) it has become more common for small quantities of dispensers to be shipped directly to a customer's home. Often the packaging for such e-commerce sales is not as robust as the corrugated cartons that may be used for large lots of product. Conventional locking features may not adequately protect the dispenser contents from opening or leaking during shipment. Dispensers with rotatable heads may experience unlocking, opening, and leakage. There remains a need for a dispenser with a strong locking action to provide good product security during shipment and especially for e-commerce use.
BRIEF SUMMARY OF THE INVENTION
[0006] A fluid dispenser includes a dispenser head adapted for remaining securely closed during shipping and handling. The dispenser head is rotatable between a lock-down position and an unlocked position, and rotation of the dispenser head in the vicinity of the lock-down position requires a greater torque than rotation of the dispenser head apart from the lock-down position.
[0007] The greater torque required to rotate from the lock-down position may be due to an interference of parts. In certain embodiments, the interference may be between a protrusion on the one part and a groove on another part. In other embodiments, the interference may be between a ramped protrusion and a rib. In still other embodiments, the interference may be between a first thread and a second thread, where one or both threads include a locally nonuniform thread size or a locally nonuniform thread pitch. In other embodiments, a locking ring may be frangibly connected to the dispenser head and may be broken loose in order to unlock the dispenser. The frangible connection itself may be considered an interference fit. In other embodiments, one or more latches may prevent the dispenser head from rotating until the latches are released.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] While the specification concludes with claims particularly pointing out and distinctly claiming particular embodiments of the present invention, various embodiments of the invention can be more readily understood and appreciated by one of ordinary skill in the art from the following descriptions of various embodiments of the invention when read in conjunction with the accompanying drawings in which:
[0009] FIG. 1 is an exploded perspective view of the parts of a dispenser, include a dispenser head;
[0010] FIG. 2 is a side view of the dispenser head of FIG. 1 in a closed, locked position;
[0011] FIG. 3 is a side view of the dispenser head of FIG. 1 in a closed, unlocked position;
[0012] FIG. 4 is a side view of the dispenser head of FIG. 1 in an open position;
[0013] FIG. 5 is a cross section of the FIG. 2 closed, locked position;
[0014] FIG. 6 is a cross section of the FIG. 3 closed, unlocked position;
[0015] FIG. 7 is a cross section of the FIG. 4 open position;
[0016] FIG. 8A is an exploded perspective view of certain parts of the dispenser head of FIG. 1
[0017] FIG. 8B is a detail view from FIG. 8A ;
[0018] FIG. 9 is a partial cross section view of certain parts of the dispenser head of FIG. 1 in a closed, locked position;
[0019] FIG. 10 is a side view of another dispenser head in a closed, locked position;
[0020] FIG. 11 is a side view of the dispenser head of FIG. 10 in a closed, unlocked position;
[0021] FIG. 12 is a side view of the dispenser head of FIG. 10 in an open position;
[0022] FIG. 13 is a cross section of the dispenser head of FIG. 10 in a closed, locked position;
[0023] FIG. 14 is a cross section of the dispenser head of FIG. 11 in a closed, unlocked position;
[0024] FIG. 15 is a cross section of the dispenser head of FIG. 12 in an open position;
[0025] FIG. 16 is a perspective view of certain parts of the dispenser head of FIG. 10 in an open position;
[0026] FIG. 17A is a perspective view of certain parts of the dispenser head of FIG. 10 in a closed, locked position;
[0027] FIG. 17B is a detail view from FIG. 17A ;
[0028] FIG. 18 is a side view of yet another dispenser head in a closed, locked position;
[0029] FIG. 19 is a side view of the dispenser head of FIG. 18 in a closed, unlocked position;
[0030] FIG. 20 is a side view of the dispenser head of FIG. 18 in an open position;
[0031] FIG. 21 is a cross section of the dispenser head of FIG. 18 in a closed, locked position;
[0032] FIG. 22 is a cross section of the dispenser head of FIG. 19 in a closed, unlocked position;
[0033] FIG. 23 is a cross section of the dispenser head of FIG. 20 in an open position;
[0034] FIG. 24 is a partial cross section view of certain parts of the dispenser head of FIG. 18 in a closed; locked position;
[0035] FIG. 25 is a perspective view from below of another dispenser head;
[0036] FIG. 26 is a perspective view from the front of the dispenser head of FIG. 25 along with a locking ring;
[0037] FIG. 27 is a perspective view of the dispenser head of FIG. 26 assembled onto the locking ring;
[0038] FIG. 28 is a perspective view of the dispenser head of FIGS. 25-27 , is an open position;
[0039] FIG. 29 is a perspective view from the side of another dispenser head and locking ring;
[0040] FIG. 30 is a detail view from below of the locking ring of FIG. 29 ;
[0041] FIG. 31 is a perspective view from the front of the dispenser head and locking ring of FIG. 29 , in a closed, locked position;
[0042] FIG. 32 is a perspective view from the side of the dispenser head and locking ring of FIG. 29 , in an open position;
[0043] FIG. 33 is a perspective view from the front of a dispenser head and locking ring showing another method of more tightly closing a dispenser; and
[0044] FIG. 34 is a perspective view from the side of a dispenser head and locking ring showing another method of more tightly closing a dispenser.
DETAILED DESCRIPTION OF THE INVENTION
[0045] As shown generally in FIGS. 1-34 , embodiments of the present invention are generally directed to a dispensing closure for pump-type dispensers. As shown in FIG. 1 , a pump dispenser 100 may be attached to a container 200 holding a fluid 220 to be dispensed. The pump dispenser 100 may include, from top to bottom, a dispenser head 110 , a chaplet or locking ring 130 , a container closure 150 , and a pump engine 160 . Container closure 150 may fit onto the mouth 210 of a container 200 , for example by a threaded connection as shown, or by other methods such as a bayonet or snap-on closure. Parts of the pump engine 160 may include a piston stem 169 , spring 168 , lock cylinder 167 , piston seal 166 , dispenser seal 165 , ball valve 164 , accumulator 163 , gasket 162 , and dip tube 161 . The dip tube 161 may extend into the container 200 . Pump dispenser 100 may pump liquid 220 from the container 200 . Pump dispenser 100 may be provided with lock-down features as described in the following paragraphs.
[0046] Various elements may be included in the pump dispenser that require a greater unlocking torque T 1 when rotating the dispenser head from a locked position to an unlocked position, than the usual torque T 2 required when rotating the dispenser head from an unlocked position to an open or use position. These elements may include an interference fit between certain parts of the dispenser head. By “interference fit” is meant a physical interaction between the shapes of the parts that locally requiring a greater torque to rotate the dispenser head. Thus the interaction between the parts may cause a tighter lock condition, or a “ship-tight” condition, or an anti-rotate, anti-twist, or anti-turn condition.
[0047] FIGS. 2-4 show side views of a first pump dispenser 101 with locking feature in three positions: closed and locked-down, unlocked, and open or use position. To move from the closed/locked to the unlocked position, dispenser head 110 is rotated sufficiently with respect to locking ring 130 so that the dispenser is unlocked. Further rotation of dispenser head 110 brings it to a fully open position. Particularly in FIG. 4 , certain features are denoted including dispenser head depending skirt 113 and dispenser head outer barrel 112 . Locking ring 130 may include a lower rim 131 , a cylindrical wall 133 , and an upper rim 135 .
[0048] An interference fit may be provided by a protrusion such as locking ramp 140 shown on the upper rim 135 of locking ring 130 . The operation of the locking ramp will be explained further with regard to the cross section views of FIGS. 5-7 , which correspond to the side views of FIGS. 2-4 .
[0049] As shown in the closed, locked position of FIG. 5 , locking ramp 140 on locking ring 130 may engage a locking rib 116 on the underside of dispenser head 110 . The engagement of locking ramp 140 and locking rib 116 may occur at or near the point where the dispenser head 110 has been rotated completely downward on threads 118 , 132 . To engage or disengage locking ramp 140 and locking rib 116 may require more torque than is needed for otherwise rotating the dispenser head 110 on the locking ring 130 . As a non-limiting example, the torque required to disengage locking ramp 149 and locking rib 116 may be about 13 inch-lbs. After the locking features are disengaged, the torque for further rotation of the dispenser head 110 on the locking ring 130 may be about 2 inch-lbs. The extra torque for disengaging the locking feature may need only to be exerted for a few degrees of rotation before the locking feature is disengaged. As a non-limiting example, the extra torque may be required for only about 2-5 degrees of rotation. The locking features may include a single locking ramp 140 and locking rib 116 . However, multiples of these features may also be utilized, such as one or more additional locking ramps and locking ribs for example on opposite sides of the dispenser or spaced around the circumference. One locking rib 116 may be used with more than one locking ramp 140 , or one locking ramp 140 may be used with more than one locking rib 116 .
[0050] FIG. 6 shows the dispenser in an unlocked position where the dispenser head 110 has been rotated sufficiently to disengage the locking rib 116 and locking ramp 140 . FIG. 7 shows the dispenser in an open condition where the dispenser head 110 has been rotated completely upward until threads 118 , 132 disengage to free the dispenser head 110 from locking ring 130 and allow the spring 168 to extend the dispenser head into readiness for dispensing product. The dispenser may be closed and locked again by pressing down on the dispenser head 110 until threads 118 , 132 may be reengaged and the dispenser head twisted down on the threads until the locking rib 116 and locking ramp 140 are again engaged.
[0051] FIG. 8A shows a perspective view of the dispenser head 110 , locking ring 130 with associated locking ramp 140 , and container closure 150 . FIG. 9 shows a partial cutaway of the dispenser head 110 and locking ring 130 , including two locking ramps 140 on the locking ring 130 , and two locking ribs 116 on the underside of dispenser head 110 . Also seen in this view are the dispenser head outer barrel 112 and inner barrel 114 , and the fluid outlet 111 in the dispenser head 110 . The dispenser head 110 may rotate approximately one turn from the locked position of FIG. 9 to the open position. The locking ramps 140 may be shaped so that a greater torque is required to rotate from the locking position to the unlocked position, than is required to rotate the dispenser head through most of the travel between the unlocked and open positions. The locking ramps 140 may be shaped to require a greater torque to rotate the dispenser head 110 from the locked position to the unlocked position, than to rotate the dispenser head 110 from the unlocked position back to the locked position.
[0052] FIG. 8B shows a detail view of the locking ramp 140 . As non-limiting examples, locking ramp 140 may have a width (radial direction) between 1.5-3.5 mm (about 0.060″ to 0.140″), and a height between 0.4 to 1.5 mm (about 0.015″ to 0.060″). The slope of locking ramp 140 may be approximately 20 degrees. Locking rib 116 may have a thickness between 0.5 to 1.5 mm (about 0.020″ to 0.060″).
[0053] Another pump dispenser 102 with a different locking feature is shown in FIGS. 10-17 . FIGS. 10-12 show side views in three positions respectively: a closed, locked position, an unlocked position, and a fully open/use position. Corresponding cross-section views are seen in FIGS. 13-15 . To move from the closed, locked position the dispenser head 110 is rotated sufficiently with respect to locking ring 130 so that the dispenser is unlocked. Further rotation then brings the dispenser to a fully open position.
[0054] According to various embodiments of the invention, a locking feature be provided as an interference fit in which a locking bump 142 as shown at the lower rim 131 of locking ring 130 , may engage a locking groove 120 at the base of depending skirt 113 of dispenser head 110 . The operation of the locking bump 142 will be explained further with regard to the cross section views of FIGS. 13-15 .
[0055] As shown in the closed, locked position of FIG. 13 , locking bump 142 on locking ring 130 may engage locking groove 120 on the lower edge of depending skirt 113 of dispenser head 110 . The engagement of locking bump 142 and locking groove 120 may occur at or near the point where the dispenser head 110 has been rotated completely downward on threads 118 , 132 . To engage or disengage locking bump 142 and locking groove 120 may require more torque than is needed for otherwise rotating the dispenser head 110 on the locking ring 130 . As a non-limiting example, the torque required to disengage a locking bump 142 and locking groove 120 may be about 13 inch-lbs. One the unlocking feature is disengaged, the torque required to rotate the dispenser head 110 on locking ring 130 may be only about 2 inch-lbs. The extra torque for disengaging the locking feature may only need to be exerted for a short angle until the locking feature is disengaged. As a non-limiting example, the extra torque may be required for only about 2-5 degrees of rotation. The locking feature may include a single locking bump 142 and locking groove 120 . However, multiples of these features may also be utilized, such as one or more additional locking bumps 142 ′ and locking grooves 120 ′ for example on opposite sides of the dispenser or spaced around the circumference. One locking bump 142 may be used with more than one locking groove 120 , or one locking groove 120 may be used with more than one locking bump 142 .
[0056] FIG. 14 shows the dispenser in an unlocked position where the dispenser head 110 has been rotated sufficiently to disengage the locking groove 120 and locking bump 142 . FIG. 15 shows the dispenser in an open condition where the dispenser head 110 has been rotated completely upward until threads 118 , 132 disengage to free the dispenser head 110 from locking ring 130 and allow spring 168 to extend the dispenser head into readiness for dispensing product. The dispenser may be closed and locked again by pressing down on the dispenser head 110 until threads 118 , 132 may be reengaged and the dispenser head twisted down on the threads until the locking bump 142 and locking groove 120 are again engaged.
[0057] FIG. 16 shows a perspective view in an open position including locking groove 120 and locking ring 130 with associated locking bump 142 . FIG. 17A shows a perspective view in a closed, locked position with locking groove 120 , locking ring 130 with associated locking bump 142 . In the locked position of FIG. 17A , the locking bump 142 is engaged with the locking groove 120 .
[0058] FIG. 17B shows a detail view of the locking groove 120 and locking bump 142 . As non-limiting examples, the locking bump 142 may have a trapezoidal shape with a wider base and a narrow top. The locking bump may have a height between 0.5 to 1.5 mm (about 0.020″ to 0.060″) and the locking bump may have a top that extends in the circumferential direction between 0.6-1.5 mm (about 0.024″ to 0.060″). The slope of the locking ramp sides may be approximately 30-45 degrees from vertical.
[0059] A pump dispenser 103 with a third type of locking feature is shown in FIGS. 18-24 . FIGS. 18-20 respectively show side views of closed, locked-down position, an unlocked position, and an open position. Corresponding cross section views are shown in FIGS. 21-23 . To move from the locked position the dispenser head 110 is rotated sufficiently with respect to locking ring 130 until threads 118 , 132 disengage to free the dispenser head 110 from locking ring 130 and allow spring 168 to extend the dispenser head into readiness for dispensing product. The dispenser may be closed and locked again by pressing down on the dispenser head 110 until threads 118 , 132 may be reengaged and the dispenser head twisted down on the threads until the thread interference (described below) is again engaged so that the dispenser is locked.
[0060] FIG. 24 shows a partial cross section view in a locked position of the dispenser head 110 and locking ring 130 .
[0061] In the version of the pump dispenser 103 shown in FIGS. 18-24 , the locking feature may include a thread interference fit between a portion of threads 132 on the locking ring 130 , and threads 118 on the dispenser head 110 . For example the thread interference fit may occur between the threads only when the dispenser head 110 is in the closed, locked position of FIGS. 24 and 27 . One example for achieving this is to have the upper end portions 119 , 134 of threads 118 , 132 respectively fit more tightly together than elsewhere on threads 118 , 132 .
[0062] By an “thread interference fit” of the threads is meant a mismatch in the thread fit which may require a greater torque to twist the threads relative to another, compared with the torque required to twists the threads relative to one another during most of the rotation of the dispenser head 110 relative to locking ring 130 . As a non-limiting example, the torque required to disengage the mis-fit threads may be about 5 inch-lbs, over about 2-5 degrees of rotation. After disengaging the mis-fit threads, the torque to continue rotation of the dispenser head 110 relative to the locking ring 130 may be only about 2 inch-lbs.
[0063] The upper end portions 119 , 134 may only engage each other when the dispenser head is in the down/closed/locked position. However, since the upper end portion 134 of threads 132 on the locking ring may engage through most of the rotational travel of the dispenser head 110 , it may be advantageous to form a thread interference fit only on the upper end portion 119 of thread 118 on the dispenser head 110 . Therefore upper end portion 119 may have a groove portion that is slightly narrower than usual, or a ridge portion that is slightly wider than usual, either of which may form an interference with the upper end portion 134 . Alternately the upper end portion 119 may depart from the uniform helical path elsewhere on thread 118 , in order to form an interference fit with the upper end portion 134 . Therefore the thread interference fit between the threads 119 , 134 may be either a locally non-uniform size of one or both threads, or a locally non-uniform spiral path of one or both threads.
[0064] Another example for achieving a thread interference fit between threads 132 , 118 would be to have their lower end portions respectively fit more tightly together than elsewhere on threads 118 , 132 . Since the lower end portion of thread 118 on the dispenser head may engage through most of the rotational travel of the dispenser head 110 , it may be advantageous to form a thread interference fit only on the lower end portion of thread 132 on the locking ring 130 . Therefore the lower end portion of thread 132 may have a groove portion that is slightly narrower than usual, or a ridge portion that is slightly wider than usual, either of which may form a thread interference with the lower end of thread 132 . Alternately the lower end portion of thread 132 may depart from the uniform helical path elsewhere on thread 132 , in order to form a thread interference fit with the lower end of thread 118 .
[0065] As shown in the closed, locked position of FIG. 21 , upper end portion 134 of thread 132 on locking ring 130 may have a thread interference fit with the upper end portion 119 of thread 118 on the dispenser head 110 . This thread interference fit may occur at or near the point where the dispenser head 110 has been rotated completely downward on threads 118 , 132 . Rotating the dispenser head at this extreme may require more torque than is needed for otherwise rotating the dispenser head 110 on the locking ring 130 . This may provide added resistance against accidental opening and leakage. However, the extra torque may only need to only be exerted until the locking feature is disengaged.
[0066] FIG. 25 shows a perspective view of another dispenser head 110 that initially is formed with a tear ring 170 on its lower edge. The tear ring 170 may be connected to the dispenser head depending skirt 113 by several tear ribs 176 . The tear ring 170 may have on its internal edge a plurality of ring ratchets 172 . When the dispenser head 110 is initially threaded onto locking ring 130 shown in FIG. 26 , the ring ratchets 172 will ride over retention ribs 174 provided on the locking ring 130 . Thereafter, the dispenser head 110 cannot be rotated with respect to the locking ring 130 until enough torque is applied to break the tear ribs 176 . This provides a lock-down capability during shipment, and also a tamper-evidence feature as it will be readily apparent if the tear ribs 176 have been broken.
[0067] FIG. 27 shows the dispenser head 110 assembled onto the locking ring 130 . FIG. 28 shows the dispenser head after it has been rotated upward from locking ring 130 . The tear ring 170 is held on locking ring 130 by the ring ratchets 172 , so the applied torque to initially unlock the dispenser head causes the tear ribs 176 to break and sever the connection between the locking ring 130 and the dispenser head depending skirt 113 .
[0068] The tear ring 170 may be used with other of the dispenser heads here to provide a tamper evident feature and/or additional security against unintentional unlocking of the dispenser head.
[0069] FIG. 29 shows a perspective view of another dispenser head 110 and locking ring 130 . Here the lower edge of the dispenser head depending skirt 182 is provided with a pair of notches 182 that each receive a latch 184 projecting upward from the lower rim 131 of locking ring 130 . The latches are connected to pads 186 that may be pinched inward to disengage latch 184 from notch 182 . To provide some flexibility in moving the latch, the latch 184 and pad 186 may be carried on arm 187 show from above in the simplified drawing of FIG. 30 . Arm 187 may essentially be part of the lower rim 131 , but may be separated from the lower rim 131 by an opening 188 . When pad 186 is pressed inward or downward, the arm 187 and attached latch 184 deflect inward or downward out of engagement with notch 182 , so that the dispenser head 110 may be rotated and opened. FIG. 31 shows the dispenser head 110 attached to locking ring 130 in the locked position. The arrows “P” indicate a pressing or pinching force applied to pads 186 while around “R” indicates a rotational force applied to the dispenser head 110 to rotate the head free of the latches 184 .
[0070] FIG. 32 shows the dispenser head 110 having been rotated to an open position. The dispenser head 110 may still be returned to a closed and locked position ( FIG. 31 ) by pushing down on the dispenser head 110 and rotating it onto locking ring 130 until the latches 184 once again engage the notches 182 .
[0071] Two notches 182 and two latches 184 are shown in FIGS. 29-32 . However, a single notch and latch, or more than two notches and latches, may be used.
[0072] FIGS. 33 and 34 show embodiments that may not require any changes to the initial structure of the dispenser head 110 and locking ring 130 . Instead, as shown in FIG. 33 , one or more drops of adhesive 192 may be applied at the junction of the dispenser head depending skirt 113 and the lower rim 131 of the locking ring. Sufficient adhesive may be applied to provide an initial locking strength for shipment and storage. The adhesive may be nearly invisible, for example a low viscosity clear adhesive that may reside mainly within the thin space between the depending skirt 113 and lower rim 131 . In the alternative, the adhesive may be readily apparent, for example with a higher viscosity, colored or opaque adhesive to provide a degree of tamper-evidence. Instead of using an adhesive, one or more areas around the junction of the depending skirt 113 and lower rim 131 may be spot welded as by a hot instrument to fuse together small areas which may provide a locking strength and a tamper-evident feature.
[0073] As shown in FIG. 34 , one or more drops of adhesive 194 may be applied onto thread 132 , (and/or thread 119 inside depending skirt 113 ) for example at its lower end. Sufficient adhesive may be applied to provide an initial locking strength for shipment and storage. Instead of using an adhesive, the area near the lower end of thread 132 or 119 may be deformed slightly as by a hot instrument or pressure to create enough interference between threads 132 and 119 (within depending skirt 113 ) to provide extra locking strength for the closed dispenser.
[0074] It would be appreciated by those skilled in the art that various changes and modifications can be made to the illustrated embodiments without departing from the spirit of the present invention. It would be appreciated that certain of the embodiments may be used in combinations. All such modifications and changes are intended to be within the scope of the present invention. | A pump dispenser includes a dispenser head rotatable relative to a locking ring for a lock-down feature during shipment. The lock-down feature requires a greater torque to initially rotate the dispenser head from the lock-down position, and a lesser torque to further rotate the dispenser head to a use position. The lock-down feature incorporates an interference between the dispenser head and locking ring, either inside the dispenser head, on an outer periphery of the dispenser head, or between threads connecting the dispenser head and locking ring. | 1 |
BACKGROUND OF THE INVENTION
This invention relates generally to air conditioning systems and, more particularly, to base pan structures for air conditioning systems of the type having a chassis-containing sleeve.
In a so-called PTAC (i.e., packaged terminal air conditioning) system, the apparatus is mounted in the wall by way of a sleeve which slideably receives the chassis therein. Traditionally, one of the interfaces between the sleeve and the chassis is a gasket which seals the space between the front face of the sleeve and the base pan of the chassis. This has commonly been accomplished by way of a z-shaped bracket one leg of which is secured to the bottom of the base pan and the other legs of which support a gasket attached for abutting against the inner surface of the lower wall of the sleeve when the chassis is installed so as to thereby establish a sealed relationship between the sleeve and the base pan.
It has been found that with the use of some materials the sleeve tends to sag in the middle such that when the chassis is subsequently installed, the gasket may not mate well with the sleeve lower wall to provide a good sealing relationship across the entire width. A sleeve made from a plastic material for example, is susceptible to such a phenomena since a plastic sleeve tends to sag simply from its own weight. A resulting poor sealing relationship may cause leakage of water and outdoor air into the room being conditioned.
It is therefore an object of the present invention to provide an improved packaged terminal air conditioning system installation.
Another object of the present invention is the provision in an air conditioning system for establishing a good sealing relationship between a chassis and a containment sleeve.
Yet another object of the present invention is the provision in a packaged terminal air conditioning system for the use of plastic sleeves without attendant leakage problems.
Still another object of the present invention is the provision for correcting a leakage problem associated with the deformation of containment sleeves.
Yet another object of the present invention is tbe provision for a sealing bracket which is economical to manufacture and extremely functional in use.
These objects and other features and advantages become more readily apparent upon reference to the following description when taken in conjunction with the appended drawings.
SUMMARY OF THE INVENTION
Briefly, in accordance with one aspect of the invention, the second and third legs of a conventional interface bracket are lengthened such that the third leg extends under the bottom wall of the sleeve in an overlapping manner. In this way, it provides support for the sleeve wall and maintains the wall in its proper position against the sealing gasket.
In accordance with another aspect of the invention, the third leg is so formed that its edge angles inwardly from its ends such that there is gradually less overlap toward the middle thereof. Because of this angled form, when the base pan and attached bracket are moved into place, the end portions of the third leg are the first to overlap the sleeve wall. As the overlap gradually increases, any sag that may exist in the sleeve wall will be gradually cammed upwardly into its proper position by the gradual engagement of the angled surface. In this way, a proper sealing relationship is established and maintained.
In the drawings as hereinafter described, preferred and modified embodiments are depicted. However, various other modifications and alternate constructions can be made thereto without departing from the true spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of an air conditioning system particularly suited for use with the present invention.
FIGS. 2-3 are partial sectional views of the interface bracket in accordance with the prior art.
FIG. 4 is a perspective view thereof.
FIG. 5 is a partial sectional view of the interface bracket in accordance with one embodiment of the invention.
FIG. 6 is a perspective view thereof.
FIG. 7 is a perspective view of a modified embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a typical packaged terminal air conditioning system is shown generally at 10 to include a generally rectangular shaped sleeve 11 and a chassis 12 which slides into the sleeve opening 13 in such a way that its condenser coil 14 is exposed to the outside air and its evaporator coil (not shown) communicates with the indoor air by way of a grille structure 16 in the front cover 17. A base pan 18 is provided to contain the various components in the chassis 12 and to facilitate the installation of the chassis 12 into the sleeve opening 13 where it rests on the sleeve lower wall 19.
In addition to the lower wall 19, the sleeve includes side walls 21 and 22, and top wall 23. The dotted line indicates that portion of the sleeve 11 which is contained within the wall 24, while the solid line indicates that portion which extends inwardly from the wall 24. As can be seen, a substantial portion of the sleeve 11 is cantilevered inwardly from the wall 24. This relationship may cause a sagging of the sleeve lower wall 19 with its attendant problems as mentioned in the background discussion hereinabove.
Attached to the lower surface of the base pan 18 is an interface bracket 26 which extends transversely across the width of the base pan 18 and acts to provide a sealed condition between the base pan 18 and the front face 27 of the sleeve lower wall 19. Referring to FIGS. 2-4, a typical prior art installation is shown where an interface bracket 26 is welded to the base pan 18 in such a way as to support a gasket 28 that abuts the front face 27 of the sleeve lower wall 19. The interface bracket is z-shaped in form and includes a first leg 29 that is secured to the base pan 18, a second leg 31 that extends normally down therefrom, and a third leg 32 that extends substantially normally from the end of the second leg 31 as shown. As will be seen in FIG. 4, the bracket second leg 31 includes at its ends the tabs 33 and 34 which extend upwardly from the plane of the first leg 29 for attaching the ends of the gasket 28 thereto for support thereof as shown.
The gasket 28 is secured to and supported by the second and third legs 31 and 32, respectively which closely surround its two sides as shown.
When the proper relationship exists between the sleeve lower wall 19 and the base pan 18, as shown in FIG. 2, the front face 27 of the sleeve lower wall 19 is securely engaged along its entire surface with the gasket 28 to thereby provide a proper sealing relationship between the sleeve lower wall 19 and the base pan 18. However, if the sleeve lower wall 19 tends to sag as shown in FIG. 3, then the integrity of the seal is affected and leakage of air and water into the room is likely to occur. In particular, if there is a significant delay between the time that the sleeve 11 is installed and the chassis 12 is installed into the sleeve 11, the sleeve lower wall 19 may very well sag to the position shown in FIG. 3. When the chassis 12, with its associated base pan 18 and attached interface bracket 26 is subsequently installed, a proper sealing relationship is never established and leakage is likely to occur.
The improved interface bracket of the present invention is shown at 36 in FIGS. 5 and 6. The first leg 37 is substantially the same as that of the prior art device and is attached to the bottom of the base pan 18 by welding or the like. The second leg 38 extends downwardly to a level below the plane of the sleeve lower wall 19. The third leg 39 extends normally from the end of the second leg 38, with its length being sufficient so as ro overlap a portion of the sleeve lower wall 19 and thereby engage the bottom surface 41. In this way, the third leg 39 acts to support the sleeve lower wall 19 to prevent it from sagging downwardly, thereby maintaining the desired relationship between the front face 27 of the sleeve lower wall and the base pan 18, with the gasket 28 properly sealing the interface therebetween.
Recognizing that at the time the chassis is installed, the sleeve lower wall 19 may have already sagged to the point as shown in FIG. 3 where the bracketed third leg 39 will not slide under the sleeve lower wall 19. This is particularly true near the center of the sleeve where the degree of sagging is at its greatest. Since there is no sagging at the ends of the sleeve lower wall near the side walls 21 and 22, the bracket 36 can be installed, notwithstanding the fact that the sleeve lower wall has sagged, by slightly canting it such that one of the corners 42 or 43 is the first to contact the sleeve lower wall 19. Once one of the corners 42 or 43 has been inserted into an overlapping position under the sleeve lower wall 19, then one can gradually move the overlap toward the other end such that the sleeve lower wall 19 is gradually "cammed" upwardly to a proper non-sagging position as shown in FIG. 5.
Shown in FIG. 7 is an alternative and preferred embodiment of the present invention wherein the above described camming action is automatically obtained without the need for canting of the bracket 36 during installation. As can be seen, the leading edge 44 of the third leg 39 is angled inwardly from each end to a middle point 46 where the depth of the third leg 39 is at a minimum. In installing the bracket 36, the chassis can be moved straight inwardly without canting to the side since the two corners 42 and 43 will then automatically first engage the sleeve lower wall 19. The point of engagement will then automatically move inwardly along the angled leading edge 44 to gradually cam up the sagging sleeve lower wall 19 until, finally, the middle point 46 will slide under the lower surface 41 to the supporting position as shown in FIG. 5.
It will be understood that the present invention has been described in terms of preferred and modified ebodiments, but may take on any number of other forms while remaining within the scope and intent of the invention. | The interface bracket, which supports a sealing gasket between the lower surface of a base pan and the front face of a sleeve lower wall, is designed so as to extend under the sleeve lower wall so as to overlap and support the lower wall from sagging. The integrity of the sealing relationship is therefore maintained. Provision is also made to automatically cam the sleeve lower wall from a sagged position by the use of a bracket with an angled leading edge. | 5 |
This application is a continuation application of U.S. patent application Ser. No. 09/082,789 entitled “HARD DISK DRIVE HEAD-MEDIA SYSTEM HAVING REDUCED STICTION AND LOW FLY HEIGHT” filed on May 21, 1998, now U.S. Pat. No. 6,381,090.
FIELD OF THE INVENTION
The present invention relates to hard disk drives used to store data, and more particularly to a head-media system having reduced stiction and low fly height capability.
BACKGROUND OF INVENTION
In the field of hard disk storage systems, continuous improvements have been made in increasing the areal density, i.e., the number of stored bits per unit of surface area. As is well known, decreasing the fly height of the read/write head results in reduced pulse width (PW50) due to a number of factors which allows for greater recording density. For a discussion of the effects of lower fly height, see, for example, U.S. Pat. No. 5,673,156. In any event, bringing the head closer to the media has been a key area of effort in increasing recording densities.
The read/write head is typically a part of or affixed to a larger body that flies over the disk and is typically referred to as a “slider”. The slider has a lower surface referred to as the air bearing surface. The air bearing surface typically comprises one or more rails which generally generate a positive air pressure. In addition, there is often a cavity or similar structure that creates a sub-ambient pressure to counterbalance the positive pressure to some extent. The slider body is attached to a suspension via a head gimbal assembly which biases the slider body towards the disk. The net effect of the air bearing surface and the suspension is to cause the slider to fly at the desired height when the disk is at full speed, and to cause the slider to be in contact with the disk surface when the disk is at rest. The portion of the slider that contacts the disk is typically the aforementioned one or more rails. As the fly height of the slider is reduced, it is necessary to produce disks with increasingly smooth surfaces. As is well known, the slider undergoes sliding contact with a portion of the disk whenever the drive motor is turned on or off. This contact between the slider and the disk occurring when the drive is turned on and off is known as contact start stop (CSS) operation.
The CSS motion between the slider and the disk is of great concern in the reliability of the drive since it is generally the major initiator of failure in hard disk drives. In today's commercially available disk drives, generally 20,000 CSS cycles for desk-top computer applications and up to 100,000 CSS cycles for portable or hand-held computer applications is considered adequate. A greater number of CSS cycles is needed in portable and hand-held computer applications because the drives are frequently turned on and off to conserve battery power. Recently, there has been a trend to reduce power consumption in desktop computers. Therefore it is expected that CSS requirements will greatly increase for desktop applications as well.
In order to improve the CSS performance, it is well understood that friction must be minimized between the slider and the disk. Static friction or stiction is a term used to describe the force exerted against the motion of the slider relative to the disk surface when the slider is at rest on the disk surface. Stiction values are often given in grams to represent the force required to separate the slider from the disk. The stiction is greatly increased if the lubricant that is used on the surface of most disks wets a significant portion of the slider/disk interface.
Often, the term initial stiction refers to the stiction encountered when the slider contacts the disk for a minimal amount of time, without a significant opportunity for lubricant to migrate to the slider/disk interface. Parking stiction is a term used when the disk drive has not been in use, so that the slider has been at rest on the CSS zone for some time and may have some lubricant migration to the interface. Parking stiction is typically greater than initial stiction. Finally, the term fly stiction is used to describe the situation where the slider has flown over the disk for a considerable amount of time so as to pick up lubricant, and then after returning to the disk surface has remained on the disk surface for a sufficient time to allow the lubricant to flow to and significantly wet the interface, thereby greatly increasing stiction. Stiction can be strong enough to prevent the drive motor from turning, or worse yet, can damage the head, cause the slider to become detached from the suspension assembly, or cause the slider to ding the disk surface during separation of the slider from the disk surface. (The term “ding” is used in the art to describe an abnormal and sudden impact of the slider against the disk surface which dents the disk surface around the impact area. This can occur, for example, by accidentally dropping the disk drive on a hard surface. This can also occur when the slider is stuck on the disk surface during drive start-up due to high stiction, followed by sudden release of the slider, which causes it to bounce on and thereby dent the disk surface.)
It has been recognized that stiction can be reduced by putting a “micro-texture” on the disk surface to reduce the effective contact area between the slider and the disk. See, for example, Marchon et al., “Significance of Surface Roughness Measurements. Application to the Tribology of the Head/Disk Interface,” Tribology and Mechanics of Magnetic Storage Systems VI, ASLE SP-26, page 71 (1990), which describes the roughness needed to achieve an acceptable rate of increase in stiction under prolonged CSS for a disk comprising an aluminum/NiP substrate with a near concentric texture pattern. Also, Lee et al., describe the effect of texture crossing angle on CSS performance in “Effect of Disk Cross Hatch Texture on Tribological Performance”, published in IEEE Transaction on Magnetics, Vol. 28, No. 5, September 1992, pp. 2880-2882. In effect, a rougher texture and modification of texture morphology is needed to achieve acceptable CSS performance. The texture pattern may be put on the disk by mechanically abrading the substrate surface using well known methods.
In contrast to the requirements of CSS operation, for reading or writing data it is desirable that the surface of the disk be as smooth as possible to allow the head to fly as close as possible to the disk surface. Because of these differing requirements, it is known to use zone texturing where a portion of the disk used for CSS operation (the CSS zone) is textured more heavily than the portion of the disk used for data storage (the data zone). One problem with such zone texturing, however, is that it is difficult to create a precisely delineated CSS zone with mechanical texturing methods. Because of this, some portion of the data zone is typically lost, thus reducing the amount of data a disk can hold.
Because the data zone is smoother than the CSS zone, both the glide height (minimum distance at which a slider may fly without contacting any portion of the disk surface) and the glide avalanche height (distance above mean disk surface level at which the slider makes regular and continuous contact with the disk surface) are lower in the data zone than in the CSS zone. However, because it is necessary to move the head from over the data zone to the CSS zone, the glide avalanche height of the CSS zone limits the fly height over the data zone, as the head must be able to safely move between the two zones, without undue contact in the CSS zone which could lead to wear of the disk surface, the slider, and generation of debris. It should be noted that it is difficult to produce mechanical texturing with a high degree of uniformity. This nonuniformity in surface texture means that some portions of the CSS zone may be considerably rougher than average, which poses further limitations on the fly height.
Another known method to provide the necessary texture in the CSS zone is laser zone texturing. An example of this method is described in U.S. Pat. No. 5,108,781. In such a method, a laser beam is focused to a small spot on the disk surface, forming uniformly shaped and sized features in a controllable pattern. Because of the high degree of control possible with a laser system, the CSS zone can be precisely delineated so that loss of data zone area can be minimized. Furthermore, because the size of the features is better controlled than the surface morphology resulting from mechanical texturing, the above-described uniformity problem is greatly reduced. However, because the surface in the laser texture zone has a considerably greater roughness than the data zone, the CSS zone still provides a limitation to the fly height even in laser zone textured disks. See “The Special Needs of Server Class Drives” by Wachenschwanz et al., IDEMA Insight, Vol. XI, No. 1, January/February 1998 which illustrates that laser zone texturing achieves acceptable stiction performance for today's devices and further asserts that laser based zone textured disks should be extendible for at least two generations.
Another method to reduce stiction in CSS operation is to provide a texture on the surface of the slider rather than the disk. Such sliders are frequently referred to as “padded” sliders or “stiction-free” sliders. The texture may be provided in a variety of menners. For example, “Numerical Simulation of the Steady State Flying Characteristics of a Fifty Percent Slider with Surface Texture” by Wahl et al., IEEE Transactions on Magnetics, Vol. 30, No. 6, November 1994, discloses a slider having a plurality of hemispherical, conical, or cylindrical features arranged in a densely packed pattern thereon. U.S. Pat. No. 5,079,657 teaches several varieties of textured sliders using chemical etching in one embodiment formed by differential etching, and in another embodiment formed by the use of a masked photo resist layer. “Stiction Free Slider for Lightly Textured Disks”, by D. Yamamoto et al., IEEE Trans. Mag. Vol. 34, No. 4, 1998, shows a textured slider which has one or more “pads” along the length of each rail. Herein, a slider having texture formed by any method, including the foregoing, with any type of pattern is referred to as a “textured” slider.
FIGS. 1A and 1B show two examples of textured sliders. As shown in FIGS. 1A and 1B, the sliders comprise a slider body 101 a/b coupled to suspension 102 a/b . Each of the sliders comprises two rails 103 a/b (although sliders with a single rail and sliders with more than two rails may be used). Also as shown in FIGS. 1A and 1B, each of the rails has a plurality of pads 104 a/b . In the particular slider shown in FIG. 1B, each pad 104 b may have dimensions, for example, of approximately 35-50 microns wide by 50-100 microns long. Of course other dimensions may be used.
In the above described textured sliders, the intent is to provide a slider surface that has some portions at a different elevation than others to reduce the total contact area and thereby reduce stiction. One advantage to using such sliders is that a lower roughness of the disk surface is needed to meet stiction requirements. This lower roughness is comparable to the roughness of current data zone texture, so that the entire disk surface may be textured as appropriate for data storage, thus allowing for lower fly heights and increased density. Additionally, textured sliders are intended to eliminate the need for a separate zone, whether by mechanical texturing with its concomitant loss in usable area, or laser zone texturing which typically adds a step to the disk fabrication process. In the above mentioned article by Yamamoto et al., it is stated that the stiction results obtained with the stiction free slider described therein is acceptable even on relatively lightly textured surfaces which have a roughness comparable to current data zone texture. Recently, it has been reported that a textured slider may be extendible for the next several generations of disk drives. See “Fujitsu's Padded Slider Hold Stiction at Bay”, Data Storage, May 1998, page 8.
A further approach to the stiction problem is drives using a so-called “load/unload” mechanism. In these drives, when the drive is turned off, the head is parked on a ramp and not on the disk surface. Therefore, in load/unload drives, the problem of stiction is eliminated. However, the load/unload mechanism adds to the cost and complexity of the drive.
As can be seen from the foregoing, current attempts are to either improve the disk texturing, with particular current emphasis on laser zone texturing or alternatively to eliminate the need for a separate zone by providing a textured slider or by providing a load/unload mechanism.
As recording density increases, ever smoother surfaces will be required so that heads may fly lower. Current state-of-the-art systems have glide avalanche heights in the data zone of approximately 0.8 through 1.0 microinch (μ″). In the future, glide avalanche heights of approximately 0.4μ″ or below will be needed for disks having densities in the range of approximately 3-5 gigabits per square inch (Gb/in 2 ). On a laser zone textured disk, the glide avalanche height for such CSS zone would need to be in the range of approximately 0.6-0.7μ″. An average laser bump height in the range of approximately 50-100 angstroms (Å) will provide a glide avalanche height in this range, but is likely to have unacceptably high stiction for conventional sliders. Thus, what is needed is a method and apparatus for providing a slider-head system having very low glide height and acceptable stiction performance.
SUMMARY OF THE INVENTION
A method and apparatus having a disk and body for use in a disk drive system is described. In one embodiment, the apparatus includes a disk and a body in sliding contact with a contact surface of the disk during a portion of an operation of the disk. The body has a surface comprising a pattern of features having a first distance between the features. The disk comprises at least a first zone that includes the contact surface. The first zone has a roughness comprising a plurality of protrusions having a second distance between the protrusions. The second distance between the protrusions is less than the first distance between the features.
Other features and advantages of the present invention will become apparent from the detailed description, figures and claims which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B show two exemplary types of textured sliders.
FIG. 2 shows glide avalanche height as a function of surface roughness.
FIGS. 3A and 3B illustrate the data zone and the CSS zone, respectively, of a laser textured disk.
FIG. 4 shows glide avalanche height as a function of average bump height for a laser textured disk.
FIG. 5 shows initial stiction results for a textured slider on a low roughness mechanically textured surface, and on a laser textured surface.
FIGS. 6A, 6 B, and 6 C show initial stiction over 10,000 cycles for a textured slider on a mechanically textured surface of a first roughness, a mechanically textured surface of a second roughness, and a laser textured surface, respectively.
FIG. 7 shows initial stiction as a function of glide avalanche height for an embodiment of the present invention.
FIG. 8 shows stiction results over 10,000 cycles for a textured slider on mechanically textured surfaces and on a laser textured surface.
FIGS. 9A and 9B show stiction as a function of glide avalanche height for a conventional slider and for an embodiment of the present invention, respectively.
FIG. 10 shows contact area of the slider surface as function of slicing depth.
DETAILED DESCRIPTION
A head-media system comprising a textured slider and a disk having a CSS zone with a greater roughness than a data zone. In the following description, numerous specific details are set forth such as specific sliders, disks, roughness values, etc. It will be appreciated, however, that these specific details need not be employed to practice the present invention. In other instances, well known methods and apparatuses are not described in detail in order not to obscure unnecessarily the present invention.
As described earlier, one important parameter is the glide avalanche height which is the height at which the lowest portion of the slider begins to make regular contact with the disk. Typically, the glide avalanche is stated as distance above the average surface height, typically expressed in microinches. Referring to FIG. 2, a graph of surface roughness (RMS Roughness) versus avalanche height for a mechanically textured disk surface is shown. As expected, as the surface gets smoother, the glide avalanche is reduced. As is well known in the industry, a lower glide avalanche point is needed for lower fly heights. It is believed that in disks having a density in the 3-5 Gb/in 2 range, the glide avalanche in the data zone will need to be approximately 0.4μ″. Although the CSS zone need not have as low a glide avalanche as the data zone, it too must be reduced to enable lower fly heights over the data zone, because too great a disparity in glide avalanche between the two areas would cause excessively severe wear on the slider as the head is moved back and forth, as described previously. For disks having the aforementioned 3-5 Gb/in 2 density, it is believed that the glide avalanche height in the CSS zone should be in the range of approximately 0.6-0.7μ″. Referring to FIG. 2, it can be seen that to meet the above requirements the data zone would need to have a maximum RMS roughness of approximately 10-15 Å, and the CSS zone would need to have a maximum RMS roughness of approximately 35 Å.
Also as described earlier, it is preferable not to have two mechanically textured zones because it drastically reduces the amount of space for storing data, and adds to process complexity. A disk textured in its entirety with the requisite low roughness needed for advanced densities would therefore require a surface roughness of about 15 Å RMS or lower, which corresponds to an Ra roughness of approximately 12 Å or lower.
Referring to FIG. 3A, a portion of the data surface of a disk is shown. As can be seen, the surface 300 has mechanical texturing thereon. FIG. 3B shows the CSS zone of the same disk where laser zone texturing was used. As can be seen, the surface still has mechanical texturing 300 as well as numerous laser features 301 thereon. The laser features 301 shown in FIG. 3B are generally circular, crater shaped features. It will be appreciated that other types of laser features such as the so-called “sombrero” type, or other shapes of the laser features may be used in the below described embodiments of the present invention utilizing laser texture. Typical horizontal dimensions of laser features, for example measuring from one side of the rim to the other, are in the range of about 1 micron through several microns. It will be appreciated of course that dimensions outside this range may be used in the present invention as well. The average height of the features 301 above the surface 300 is approximately 200-300 Å in most state of the art devices.
Referring now to FIG. 4, a graph of bump height as measured by an atomic force microscope (AFM) versus the glide avalanche is shown. As can be seen, a bump height in the range of approximately 200-250 Å results in a glide avalanche of approximately 0.85-1.1μ″. While this glide avalanche is acceptable for the CSS zone of current devices, as noted above a much lower glide avalanche will be required for future devices. For example, to achieve a glide avalanche of approximately 0.6μ″, an average bump height of approximately 100 Å is needed.
As will be seen it has been found by the present inventors that the use of a textured slider on a very lightly textured disk (e.g., avalanche height of about 0.4μ″) may encounter stiction problems after use. Furthermore, although considerable effort is being expended to produce textured sliders for current and future requirements, considerable development work remains. Similarly, with respect to laser texture, significant effort will be required to provide features having a low enough height for glide avalanche requirements without poor stiction performance. It would be desirable to provide for good stiction performance at low glide avalanche heights utilizing currently manufacturable technology for current and future devices. Furthermore, it would be desirable that the system be robust to provide an acceptable operating window.
To overcome these problems, the present invention comprises the use of a textured slider together with a disk having a separate zone having a greater roughness than the data zone. In one embodiment, a mechanically textured zone may be used if desired. Although this embodiment would still have the above described problems of mechanically zoned disks of the prior art, i.e. loss of some of the surface area of the disk for data storage, and greater nonuniformity than laser texturing, such an embodiment achieves improved stiction results as compared with a textured slider used on a disk textured entirely as is needed for the data zone. Alternatively, other methods of texturing may be used such as texture provided by sputtering, top surface texturing wherein the carbon overcoat is in some way treated to provide a texture, by various patterning methods to provide features, or as described in detail herein, by a method such as laser texturing.
In a particularly preferred embodiment, the invention comprises a disk having a zone that is textured by forming a plurality of features of uniform height, such as features formed by use of concentrated radiation in the CSS zone. For purposes of discussion, the latter embodiment will be discussed in conjunction with laser texturing for illustration. It will be appreciated, however, that any method of forming features with this morphology i.e. texture by way of discreet and relatively uniform protrusions, as opposed to random surface texturing characteristic of mechanical texturing processes and some chemical texturing processes, will provide the benefits of this embodiment. As will be seen, by use of this method, stiction results approximately equivalent to results achieved with a stiction-free slider when used on a mechanically textured surface of high roughness are achieved. Because of the use of a textured slider, the average laser feature height can be very low, such as 100 Å for disks storing approximately 3-5 Gb/in 2 and lower heights for capacities beyond this range, without encountering the above described stiction problems of such small bumps. Because the glide avalanche height of such bumps is relatively small, the disk may be used in high density applications.
Referring to FIG. 5, a bar graph of stiction in grams is shown. The texture on the slider comprised a pattern of small protrusions or bumps over most of the surface of the rails such as is shown in the article by Wahl et al. Herein, such textured sliders will be referred to as “full texture” sliders. FIG. 5 shows the stiction for this slider on several different disk surfaces. Bar 501 shows the initial stiction on a mechanically textured portion of a disk having a glide avalanche of 0.5μ″. As can be seen, the amount of stiction is clearly within an acceptable range. Bar 502 shows the stiction in another mechanically textured region having a glide avalanche of approximately 0.45μ″, and again as can be seen the stiction is acceptable. Bars 503 and 504 show the stiction in two more mechanically textured locations on the disk, both with a glide avalanche height of 0.45μ″. However, the locations represented by 503 and 504 show the stiction results after the same slider has undergone a few hundred CSS cycles. As can be seen, the stiction has now gone well above acceptable limits and is now in the range of approximately 13-20 grams. This data suggests that some type of degradation in the condition of the slider surface occurs after a significant number of CSS cycles. It appears that the condition of the disk does not cause the degradation as each bar represents a new location on the disk. This head degradation significantly degrades the stiction performance on very smooth surfaces.
Referring now to Bars 505 , 506 , 507 , and 508 stiction results using the same slider that was used to produce Bars 501 - 504 is shown. The data for Bars 505 - 508 was generated with this slider after it had generated the data for Bars 501 - 504 so that the slider at this point has had considerable degradation. Bars 505 - 508 represent stiction results from laser textured disk surfaces that have glide avalanche heights of 0.60μ″, 0.65μ″, 0.85μ″ and 1.20μ″ respectively. The patterns of the laser features were 25 μm×25 μm, 20 μm×20 μm, 20 μm×40 μm, and 50 μm×50 μm, respectively, where the first number represents the spacing of features along the track i.e. in the circumferential direction, and the second number represents the spacing of the features radially. As can be seen, in all cases the stiction remained at acceptable levels, even though the textured slider had degraded considerably such that the stiction rose to high levels in very smooth regions.
As noted earlier, the CSS zone needs to have a glide avalanche in the range of 0.6-0.7μ″ or less in the next couple of generations of drives. As can be seen from Bars 505 and 506 , which represent zones with glide avalanche heights of 0.60 and 0.65μ″, the present invention provides acceptable stiction results for future devices. Referring back to FIG. 4, as can be seen, the average bump height to achieve this glide avalanche is approximately 100 Å. Thus, the height of the laser features is much lower than currently being used in laser textured disks which use greater average heights to avoid stiction problems.
Referring again to FIG. 5, it will be noted that the glide avalanche of the slider/disk system of the present invention (Bars 505 - 508 ) is at a higher glide avalanche than the mechanically textured regions shown in Bars 501 - 504 which have a smooth surface characteristic of data zone regions. In embodiments using a mechanically textured CSS zone, the mechanically textured region should have a similar glide avalanche as the laser texturing used in FIG. 5 to achieve comparable results. However, importantly, the laser texture embodiment avoids having the need to produce a mechanically zoned disk that loses valuable data storage area. In any embodiment, the present invention avoids having to limit the data zone roughness by the higher roughness needed for acceptable stiction performance in future devices.
FIGS. 6A-6C illustrate the improvement achieved with the present invention. FIGS. 6A-6C show initial stiction in grams versus cycle number, for 10,000 cycles. The textured slider used in FIGS. 6A-6C was again a full texture slider. In the graph of FIG. 6A, the slider was used on a very smooth mechanically textured surface. The surface had a roughness Ra in the range of approximately 10 Å and a glide avalanche height of approximately 0.4-0.5μ″. As can be seen, the stiction quickly exceeded 10 grams after several cycles, and exceeded 30 grams after a couple thousand cycles.
FIG. 6B shows initial stiction for a textured slider on a mechanically textured surface having an average roughness Ra of approximately 16 Å. As can be seen, by using a higher roughness the stiction results are greatly improved with the stiction being slightly over 10 grams after 10,000 cycles. The results can be further improved by providing an even rougher surface in the CSS zone. Note that the roughness of approximately 16 Å is much lower than the approximately 35 Å roughness upper limit needed for the CSS zone for producing systems in the 3-5 Gb/in 2 range. Thus, FIG. 6B illustrates the benefits of a mechanically textured zone having a roughness greater than the data zone.
Referring to FIG. 6C, the stiction versus cycle for 10,000 cycles for a disk having laser features thereon is shown. In the graph of FIG. 6C, the CSS zone had laser textured features with an average height of approximately 85 Å and a glide avalanche height of approximately 0.6μ″. As can be seen, the typical stiction value is well under 5 grams (with the exception of 1 parking stiction event as shown by the spike in the graph) for the entire 10,000 cycles. The average initial stiction in FIG. 6C after 10,000 cycles was approximately 2.3 grams. The maximum stiction, other than the parking event, was 4.5 grams. This compares particularly well to the first 10,000 cycles of FIG. 6 A. In comparing the graphs, note the scale difference in the Y axis.
FIG. 7 further shows the results of the present invention. Shown in FIG. 7 is the average initial stiction in grams versus the avalanche height for a full texture head on a laser textured surface. As can be seen, by use of the present invention the stiction can be kept to acceptable levels even when the glide avalanche is below 0.5μ″. Thus, the present invention will allow for acceptable stiction performance on disks having low glide avalanche in the CSS zone, as required by future 3-5 Gb/in 2 devices and beyond.
FIG. 8 again shows the improvement achieved with the present invention. Curves 801 , 802 , 803 , and 804 show stiction in grams as a function of CSS cycle. The slider design used in all of Curves 801 - 804 was a four pad design similar to the design illustrated in FIG. 1B, with two of the pads 104 b on each of two rails. Curves 801 and 802 show the results for the slider when used on a mechanically textured surface having an Ra roughness of approximately 10 Å. As can be seen, the initial stiction is marginal at about 5 grams and after approximately 100 cycles increases up to approximately 10 or more grams, which increase is believed to be due to head degradation as described earlier. Curve 803 was generated using the same type of slider but on a mechanically textured surface having an Ra roughness of approximately 20 Å. As can be seen, the stiction behavior is generally very good. Finally, Curve 804 was generated with the same type of slider but on a CSS zone having laser features. The laser features had an average height of approximately 85 Å and a glide avalanche height of approximately 0.6μ″. As can be seen, even after 10,000 cycles, the stiction remained below 2 grams. It should be further noted with respect to curves 803 and 804 that not only do these embodiments of the present invention achieve low stiction, but the stiction remains low over many cycles, indicating that the present invention is relatively insensitive to degradation of the textured slider.
As shown in FIGS. 5-8, the present invention provides for reduced stiction when using a textured slider on a CSS zone in accordance with the present invention. FIGS. 9A and 9B illustrate the improvement of the present invention as compared with a non-textured slider. First referring to FIG. 9A, a graph of avalanche height versus stiction in grams is shown. In FIG. 9A, curve 901 shows the results for the conventional slider on a laser textured surface and the Curve 902 shows the conventional slider on a mechanically textured surface. As can be seen, the stiction with a conventional head on a laser textured surface typically reaches unacceptable values at a glide avalanche height of around 0.8μ″. The stiction on the mechanically textured surface reaches unacceptable levels at approximately 0.7μ″. The stiction response is generally more gradual on the mechanically textured surface as compared with the laser textured surface because the laser textured surface generally has peaks with relatively uniform heights, so that the surface area contacted increases much more rapidly on a laser textured surface as the slider is moved closer to the disk.
Referring now to FIG. 9B, a graph of avalanche height versus initial stiction for a full texture slider is shown. Curve 905 shows the results for the textured slider on a mechanically textured surface. As can be seen, the stiction results are improved over FIG. 9A by virtue of the use of the textured slider. Curve 906 shows the stiction results for the textured slider on a surface having laser texturing. As shown by curve 906 , the use of a textured slider on a CSS zone having laser features dramatically improves the initial stiction. As can be seen, in contrast to FIG. 9A the stiction remains under 5 grams at 0.8μ″ glide avalanche height and on average remains below this value to about 0.4μ″ glide avalanche height.
FIG. 10 shows a bearing ratio curve for several types of sliders. The curves show the percent of the slider area in contact with the surface as a function of distance from the disk surface. The chart shows the contact area in mm 2 of the slider as a function of slicing depth into the surface of the slider—i.e. a depth of zero indicates the first point of contact with greater contact at greater slicing depths. Curves 1001 , 1002 , and 1003 show current designs having a contact area of approximately 1.4 mm 2 . Curves 1005 - 1010 show so called “pico” sliders which have a reduced form factor and have a lower total contact area of approximately 0.6 mm 2 used in advanced designs. The curves 1009 and 1010 represent curves for textured sliders. Because the sliders have some type of texture, the area increases very slowly with slicing depth as compared with non-textured sliders. It has been found that the present invention works well with all types of textured sliders. In particular however, the best results appear to be obtained with sliders that have numerous point contact areas such as that shown in the article by Wahl et al., or other sliders with multiple points of low surface area contact such as some of the sliders shown in U.S. Pat. No. 5,079,657, or sliders according to the teachings of U.S. Pat. No. 5,673,156. It will be appreciated that any textured sliders including the foregoing, or sliders having a combination of the various types of textures, such as a pattern of small protrusions in one portion, and a single large area pad in another, may be used in the present invention.
The laser features on the disk in laser texture embodiments were made and formed using conventional patterns. As described herein, the typical average height of the laser texture features may be much less than is used with a non-textured slider. For example, laser features in the range of approximately 50 Å-150 Å provide for lower glide avalanche, needed to improve fly height in the data zone. Further, reduced laser feature height may be used in future devices requiring even lower glide avalanche height. However, by use of a textured slider, the stiction is considerably reduced compared with that which would be obtained by use of a conventional slider on such small laser features.
In designing the laser texture pattern one consideration is that the pattern should be such to ensure that the textured surface contacts the laser features. For example, in the padded slider shown in FIGS. 1A and 1B, the radial spacing between the laser features should be less than the width of the narrowest pad, (e.g., less than approximately 35-50 μm radial spacing for the exemplary dimensions given in conjunction with FIG. 1B) so that it is ensured that each pad lands on a laser feature. Similarly, the distance between each laser feature in the circumferential direction should be no more than the length of the shortest pad (e.g. less than approximately 50-100 μm circumferential spacing for the exemplary dimensions given in conjunction with FIG. 1 B). In this way, the elevated portions on the slider are ensured to contact the texture features on the disk to minimize surface area contact and therefore stiction. As used herein, the higher or greater elevation on a slider is considered to be a portion closer to the disk surface than other portions. For sliders that comprise texturing over a greater area, such as sliders having a plurality of protrusions over the entire surface and sliders with stripes and bars, the laser feature pattern can be less dense than for the sliders having a limited number of pads.
While the invention has been described with respect to specific embodiments thereof, those skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the invention. The use of a textured slider and a disk having a CSS zone with a rougher texture provides the ability to achieve low fly heights, while achieving acceptable stiction in the CSS zone. In one embodiment, a texture comprising precisely placed features of uniform height, such as those formed by radiant energy focused to a spot on the disk, is used. The precise placement allows for a precisely delineated CSS zone maximizing area usable for data storage. The good uniformity reduces the margin that must be added to the fly height to account for the highest peaks in the CSS zone. Preferably, the ±3 sigma uniformity is approximately ±20%, more preferably ±15% and most preferably ±10% or better. Although the latter embodiment has been described using laser texture features, any type of method that produces a similar morphology, such as use of concentrated radiant energy, or other methods, such as by performing a patterning and etch step on the disk surface, achieves these advantages. However, any type of texture may be used in the CSS zone provided it is sufficiently rough to achieve the stiction performance described herein. Furthermore, as mentioned earlier, numerous types of textured sliders may be used. The embodiments described herein, as well as embodiments having such changes in form and detail come within the scope of the present invention. | A disk drive system including a disk having a contact surface and a slider having a surface with a pattern of features is described. The disk's contact surface is textured with protrusions that roughen surface. The distance between the protrusions on the disk is less than the distance between the features on the slider surface. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This invention claims the benefit of priority to U.S. Provisional Application Ser. No. 61/519,063 filed May 16, 2011.
FIELD OF INVENTION
This invention relates to outdoor and indoor rolling games, and particular to games, stations, ramps and methods of play where one or more participants physically rolls wheels towards a ramp which leads to a box, and a target area, such as circular hole or rectangular hole where player(s) accumulate points under selected playing rules.
BACKGROUND AND PRIOR ART
Various types of yard games, activities and sports, such as horseshoes, lawn darts, bowling and toss games have become popular because of the social aspects, the physical activity, and inclusiveness of different age, gender and ability to compete.
For example, beanbag, sandbag and disc tossing type games have been used many times over the years. See for example, U.S. Pat. Nos. 922,717 to Parker; 3,628,793 to Mudloff; 4,726,591 to Johnson; 4,974,858 to Knowlton; 5,056,796 to Conville; 5,553,862 to Konotopsky; 6,866,268 to Christianson; and 7,607,666 to Studier.
Other types of games, such a ball rolling games have been proposed. See for example, U.S. Pat. Nos. 607,020 to Dodge; 742,416 to Hall; 945,286 to Rumpf; 1,262,314 to Downey; 1,545,329 to Johnston Jr.; 1,561,934 to Kennedy; 1,604,846 to Nelson; 3,837,653 to Fox et al.; and 4,726,591 to Johnson.
Some games have attempted to use rollable rings and discs. See for example, U.S. Pat. Nos. 2,662,518 to Luthi; 3,386,737 to Burgess; 5,199,708 to Lucas; and 5,664,776 to Mateer.
While these games may be suitable for the particular purpose to which they address, they are not the same and would not be suitable for all the purposes of the present invention as hereto described.
SUMMARY OF THE INVENTION
A primary objective of the present invention is to provide games, stations, ramps and method of play where one or more participants physically rolls wheels towards a ramp which leads to a box, and a target area, such as circular hole or rectangular hole where player(s) accumulate points under selected playing rules.
A secondary objective of the present invention is to provide a self-contained game assembly that can be assembled from a wheeled box, and where one or more participants physically rolls the wheels that are used for the transportable box towards a ramp which leads to a box, and a target area, such as circular hole or rectangular hole.
A third objective of the present invention is to provide a wheeled box that can serve as both a sitting stool for a participant and for a game that can be assembled from a wheeled box, and where participants physically rolls the wheels from the box towards a ramp which leads to a box, and a target area, such as circular hole or rectangular hole.
A fourth objective of the present invention is to provide a physical wheel rolling game for one or more participants, intended for a large playing area outside or inside if the room permits, where the participants roll wheels into a target assembly to garner points in competition.
A fifth objective of the present invention is to provide a physical wheel rolling game for one or more participants, having a target area that can be interchanged overtime.
The game can be comprised of one or two portable box units, each unit having two wheels that can be removed for play. The box can have a fold down side that can double as a ramp for play, where wheels from the box can be used by players to roll up the ramp and toward a target area such as circular hole or rectangular hole.
The box unit or two box units can be collapsed into components that can be carried in a single suitcase.
Another box version can have extendable handles, and wheels on two lower corners of the box, to allow the box to be moved similar to a hand truck. The wheeled box unit can have a hinged upper lid/cover that can access a space that can be used as cooler. Slots in the handle and/or on the box can be used for scoring. Removable pegs can be inserted and moved along the series of holes to update player scores.
Another version of the game can have a ramp and back panel that are foldable with one another, along with a slot in the ramp. An additional slot can be placed in the rear panel to add difficulty to game play.
Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a top view of the wheel game with holes station and folding ramp.
FIG. 2 is a rear view of the station of FIG. 1 .
FIG. 3 is a side view of the station of FIG. 1 .
FIG. 4 is a front view of the station of FIG. 1 .
FIG. 5 is a front perspective view of the station of FIG. 1 .
FIG. 6 is a rear perspective view of the station of FIG. 1 .
FIG. 7 is a front perspective view of the station of FIG. 1 showing a wheel being rolled up the ramp and into box.
FIG. 8 is a rear perspective of the station of FIG. 7 showing the wheel being rolled into box and through the keyhole cutout in the back panel for extra point(s).
FIG. 9 is a perspective view of a play setup with two stations with wheel paths toward the stations.
FIG. 10 is an exploded view of the station of FIG. 1 disassembled for storage into carrying case.
FIG. 11 is an exploded view of all components for two wheel stations along with 4 wheels for game play oriented for storage into the two stations caps which serve as part of the carrying case.
FIG. 12 is a perspective view of the components in FIG. 11 stacked for storage.
FIG. 13 shows the stacked components of FIG. 12 placed in a lower station cap for storage.
FIG. 14 is a perspective view of FIG. 13 with the upper station cap in place and thumb screws used to secure station caps to each other.
FIG. 15 is a front view of the assembled game station case of FIG. 14 .
FIG. 16 is a side view of the game station case of FIG. 15 .
FIG. 17 is a perspective view of an optional wheel of the game stations of FIG. 11-12 for play with hub plates positioned for assembly.
FIG. 18 is a perspective view with hub plates assembled. The plates can be used for logo or advertising information or just to dress up the wheel.
FIG. 19 is a front view of FIG. 18 with the wheel and hub plates assembled.
FIG. 20 is a side view of wheel with the hub plates assembled of FIG. 19 .
FIG. 21 is a cross-sectional view of the wheel with hub plates assembled of FIG. 19 along arrow 21 Y.
FIG. 22 is a top perspective view of the wheel station box of FIGS. 1-9 with optional holes and pegs for scoring.
FIG. 23 is a front view of a mobile station with cooler and a seat portion on the station.
FIG. 24 is a side view of the mobile station of FIG. 23 with cooler and seat.
FIG. 25 is a rear view of the mobile station of FIG. 23 .
FIG. 26 is a side cross-sectional view of the mobile station of FIG. 27 along arrow 26 X.
FIG. 27 is a front view of the mobile station of FIG. 25 with extendable handle up, cooler cover open, and ramp folded down for play.
FIG. 28 is a front perspective view of the mobile station with closed ramp of FIG. 23 .
FIG. 29 is a rear perspective view of the mobile station with closed ramp of FIG. 28 .
FIG. 30 is a front perspective view of the closed ramp of the station of FIG. 28 with handle extended and cooler open.
FIG. 31 is a front perspective view with the handle down, cooler closed, and ramp down for play.
FIG. 32 is a front perspective view showing stations set up for play with the wheels removed and the folding feet folded up. The path of wheel onto the ramp and into the station is shown.
FIG. 33 is an enlarged view of the upper corner of the station of FIG. 32 with scoring holes and pegs.
FIG. 34 is another enlarged view of the upper corner of the station of FIG. 22 with scoring holes and pegs.
FIG. 35 is a front perspective view of the portable folding ramp version of the wheels with holes invention.
FIG. 36 is a rear perspective view of the FIG. 35 folding ramp.
FIG. 37 is a side view of the FIG. 35 folding ramp.
FIG. 38 is a front view of the FIG. 35 folding ramp.
FIG. 39 is top view of the FIG. 35 folding ramp.
FIG. 40 is a back view of the FIG. 35 folding ramp.
FIG. 41 is a perspective view of the FIG. 35 folding ramp.
FIG. 42 is a front perspective view of the FIG. 35 folding ramp showing path of wheel up ramp and into the hole.
FIG. 43 is an exploded view of the ramp of FIG. 35 with Corn Hole insert ready for installation into the hole in ramp.
FIG. 44 is a perspective view of the FIG. 43 ramp with Corn Hole insert installed for conversion to Corn Hole play.
FIG. 45 is a perspective view of the Corn Hole converted ramp showing path of a bean bag into the converted game.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its applications to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
A listing of components will now be described.
10 . Folding Wheel Hole station. 20 . Station ramp. 22 . extension pins to pivot ramp 20 29 . track 30 . Station cap and half of carrying case. 40 . Keyhole in back of station for extra scoring potential. 50 . Stiffening brace. 52 . end slots 54 . side slots 56 . middle slot 60 . Left side. 61 . fastening hole 62 . notched bottom edge 65 . angled cut-out groove 70 . Right side. 71 . fastening hole 72 . notched bottom edge 75 . angled cut-out groove 80 . Rear panel. 81 . fastening hole 84 . notched bottom edges 86 . notched middle edge 90 . Thumb screw for assembling station. 100 . Wheel. 105 . tire 110 . Wheel path into station. 120 . Wheel path out of station should the wheel go through the keyhole in the back panel. 130 . Two disassembled complete Wheel Hole stations along with four wheels for playing the game stacked for packaging into carrying case. 140 . Handle for assembled carrying case. 150 . Backing plate with threaded inserts for assembling carrying case. 160 . Threaded insert in station cap for handle assembly. 170 . Components for two Wheel Hole stations (less station caps) and four wheels for playing the game stacked for packaging (less station caps). 180 . Complete Wheel Hole game packed and ready to carry. 190 . Optional hub plate for wheel (female connector). The connector could be screw fit, press fit, or snap fit. Two plates can be used per wheel; male and female. 200 . Optional hub plate for wheel (male connector). The connector would match the female hub plate configuration (screw, press, or snap fit). 210 . Male connector on hub plate. 220 . Female connector on hub plate. 230 . Hole in wheel through which the hub connectors pass to mate and secure the plates to the wheel. 240 . Optional scoring peg. 250 . Optional holes in station cap for scoring peg progression. 260 . Rolling mobile Wheel Hole station. Top portion incorporates a ice cooler. Two stations can play game. 265 . rectangular upright box 270 Fold down ramp. 272 . track indicia on ramp 275 . hinge 278 . fastening edge of ramp 280 . Extendable handle incorporates optional scoring holes to house scoring pegs. 290 . U-brackets secure extendable handle to body of station. 300 . Hinged cooler cover/lid doubles as a seat. 310 . Optional holes in handle for scoring peg progression. 320 . Lift handle on back of station. 330 . Cooler cover hinge. 340 . Rolling wheel for station mobility. 350 . Folding foot. 360 . Keyhole in back of mobile station for extra scoring potential. 370 . Ice cooler incorporated into top of station. 380 . Lower cavity of station receives wheel when “pitched”. 390 . Portable folding ramp version of Wheel Hole game. 400 . Main ramp with hole target for wheel. 402 . track indicia 410 . Hinged support panel tilts ramp up for play. 420 . Hole in main ramp for wheel target. 430 . Recess ledge in ramp hole accepts insert to convert game to popular Corn Hole bean bag game 440 . Keyhole cut out in support panel offers extra scoring potential. 450 . Hinge for support panel. 460 . Wheel path onto and up ramp toward target hole. 470 . Corn hole conversion insert fits into Wheel Hole target hole and rests on ledge in hole. 480 . Bean bag target hole in insert. 490 . Bean bag is thrown into target hole in insert. 500 . Path of bean bag into target hole in insert. 510 . Thread-on wheel retaining cap. This could be a wing nut or any style of hand tightened fastener. 520 . Threaded wheel axle. 530 . Foot axle upon which fold-up foot rotates to fold up and out of the way for play.
Wheel Hole Station and Carrying Case
FIG. 1 is a top view of the wheel game with holes station 10 and folding ramp 20 . FIG. 2 is a rear view of the station 10 of FIG. 1 . FIG. 3 is a side view of the station 10 of FIG. 1 . FIG. 4 is a front view of the station 10 of FIG. 1 . FIG. 5 is a front perspective view of the station 10 of FIG. 1 . FIG. 6 is a rear perspective view of the station 10 of FIG. 1 .
Referring to FIGS. 1-7 , the wheel game with holes station 10 is shown assembled. The station 10 can include a box configuration having a station cap 30 which also can function as half of a carrying case, left side 60 , right side 70 , rear panel 80 . The station can further include a keyhole shaped slot 40 in back of the station for extra storing potential. Additionally, a stiffening brace 50 can be used for supporting the left and right sides 60 , 70 and rear panel 80 . On opposite sides of the cap 30 can be fasteners 90 , such as thumbscrews for fastening the cap 30 to fastening holes in the sides 60 , 70 and panel 80 .
FIG. 7 is a front perspective view of the station 10 of FIG. 1 showing a wheel 100 being rolled up the folded down ramp 20 along a path 110 and into box of the station 10 . Indicia 29 , such as track lines can be formed on the ramp 20 to aid the user in aiming into the box station 10 . FIG. 8 is a rear perspective of the station 100 of FIG. 7 showing the wheel 100 being rolled into the box station 10 and through the keyhole cutout 40 in the back panel 80 and out 120 for extra point(s).
FIG. 9 is a perspective view of a play setup with two stations 10 with wheel paths 110 toward the stations 10 . The covers 30 on each station 10 can also function as seats for the players, so that the players can play or rest in seating positions.
FIG. 10 is an exploded view of the station 10 of FIG. 1 disassembled for storage into carrying case 180 to be described later. Referring to FIGS. 1-7 and 10 , the user can place stiffening brace 50 on the ground in order to mount the sides 60 , 70 and rear panel 80 .
Notched bottom edges 62 and 72 on the bottom rear corners of sides 60 , 70 can be pressed into mating slots 52 on opposite ends of the brace 50 and snapped (or friction fitted) into place. Notched bottom corner edges 84 of rear panel 80 can be pressed into respective slots 54 on brace 50 and also and snapped (or friction fitted) into place. And central notched bottom edge 86 of rear panel 80 can be pressed into mating middle slot 56 of brace 50 and snapped (or friction fitted) into place.
Next, the rear extension pins 22 can be slid down into inwardly facing angled cut-out grooves 65 , 75 of the sides 60 , 70 , so that the ramp 20 can pivot relative to the sides 60 , 70 .
Finally, the cap cover 30 can be fit over the tops of sides 60 , 70 and rear panel 80 , and fasteners 90 , such as thumb screws, can attach through side hole(s) 31 (only one is shown) of the cap 30 into mating fastener holes 61 , 71 , 81 of the sides 60 , 70 and rear panel 80 .
FIG. 11 is an exploded view of all components 130 for two wheel stations 10 along with 4 wheels 100 for game play oriented for storage into the two stations caps 30 which serve as part of the carrying case 180 (shown in FIG. 14 . A handle 140 can have one end attached the lower cap 30 by fastener 90 (such as a thumbscrew) that attaches to a threaded insert 160 in the cap 30 .
FIG. 12 is a perspective view of the components in FIG. 11 stacked 170 for storage between caps 30 with backing plates 150 attached to inner side edges of lower cap 30 by fasteners 90 .
FIG. 13 shows the stacked components 170 of FIG. 12 placed in a lower station cap 30 for storage. FIG. 14 is a perspective view of FIG. 13 with the upper station cap 30 in place and thumb screws 90 used to secure each of the station caps 30 to each other to be used as a carrying case 180 . The top end of handle 140 is similarly attached to the side of upper cap 30 by another fastener 90 , such as a thumbscrew. FIG. 15 is a front view of the assembled game station case 180 of FIG. 14 . FIG. 16 is a side view of the game station case 180 of FIG. 15 .
FIG. 17 is a perspective view of an optional wheel 100 having tire 105 about a rim of the game station components 130 of FIG. 11-12 for play with hub plates 190 , 200 positioned for assembly. The tire 105 can be formed from material such as but not limited to rubber, plastic, compositions, wood, and the like. Male connector 210 on hub plate 200 can pass through hole 230 in wheel 100 and snap into female receptacle 220 in opposite hub plate 190 . FIG. 18 is a perspective view with hub plates 190 , 200 assembled on the wheel 100 . The plates can be used for logo or advertising information or just to dress up the wheel 100 . FIG. 19 is a front view of FIG. 18 with the wheel 100 and hub plates 190 , 200 assembled. FIG. 20 is a side view of wheel 100 with hub plates 190 , 200 assembled of FIG. 19 . FIG. 21 is a cross-sectional view of the wheel with hub plates assembled of FIG. 19 along arrow 21 Y.
FIG. 22 is a top perspective view of the wheel station 10 of FIGS. 1-9 with optional holes 250 and pegs 240 on the cap 30 for scoring. The player(s) can move the peg(s) 240 to the right or to the left to show the progression of scoring.
Portable Wheel Station for Wheel Game
FIG. 23 is a front view of a mobile station 260 with cooler 370 and cover/lid 300 which also can function as a seat. FIG. 24 is a side view of the mobile station of FIG. 23 with cooler 370 and seat cover/lid 300 . FIG. 25 is a rear view of the mobile station 260 of FIG. 23 .
Referring to FIGS. 23-25 , the mobile station 260 can have a generally rectangular upright box shape 265 with an upper portion 370 having a cooler installed therein, and a lower wheel game portion that is accessible by a pivotable ramp 270 . The lower rear of the box 265 of the mobile station can have a pair of wheels 340 attached by to ends of an axle 520 and held in place by wheel retaining caps 510 . The wheel retaining caps 510 can be any type of fastener, such as but not limited to a wing nut, or another style of hand tightened fasteners.
In FIGS. 23-24 , a ramp portion 270 can be pivotally attached by a hinge 275 at the bottom to a portion of the box. The ramp portion 270 can stay in a closed position by having its' top edge 278 tightly fitted into the side slot opening of the box. Other types of fasteners, such as but not limited to snaps, latches, and the like, can further hold the ramp portion in a closed position.
The sizes of the ramp and wheels can vary depending upon difficulty of play. A wheel 340 having a diameter of approximately 6 inches, would cause the ramp portion 270 to have a length (height in closed position) of approximately 7 inches, so that rolling the wheel 340 up the downward positioned ramp 270 reduces the slot opening in the box to less than approximately 7 inches.
An extendable handle 280 having an inverted U shape can be attached to the station 260 by U shaped brackets 290 that are secured to the side walls of the station box 265 . Optional columns of holes 310 in the handle 280 can be used for scoring purposes with the use of optional pegs. Additionally, the handle 280 can be raised and lowered when points are achieved by the player(s). The handle 280 can be either raised or lowered to different positions during an actual game where the number of holes visible above or below the U-brackets 290 can indicate the current scores. The extendable handle 280 can be rigidly held in position by fasteners, and can be used to pull the station 260 onto wheels 340 for ease in transport.
On the back of the station 260 can be fixed handle 320 that allows for the mobile station to be moved about similar to a hand truck, where the user pulls back on the handle 260 to move the weight of the station onto the wheels 340 for transport.
FIG. 26 is a side cross-sectional view of the mobile station 260 of FIG. 27 along arrow 26 X with lid/cover 300 moved to an open position by raising the lid/cover 300 by hinge 330 , which allows access to the cooler portion 370 , and with ramp 270 rotated to a downward position. Handle 280 can be raised upward in play every time a score is achieved. Lower cavity 380 in the station receives the wheel 340 after it has been pitched or rolled into the station. A front side corner foot 350 is shown in the down position, which has an upper end attached to the bottom of the station 260 by a foot axle 530 . During play, the foot 350 is folded up during play so that the station can sit on the ground.
FIG. 27 is a front view of the mobile station 260 of FIG. 25 with extendable handle up 280, cooler cover/lid 300 open, and ramp 270 folded down for play. In this figure peg(s) 240 are shown and can be used to indicate different scoring during the played game, where pegs can be moved into different holes when a score is achieved. A keyhole slot 360 is shown in the back of the station 260 for extra scoring potential. Down the middle of the ramp 270 can be a track indicia 272 that allows the user a target to aim at to get a rolling wheel 340 up the ramp 270 and toward the keyhole slot 360 .
FIG. 28 is a front perspective view of the mobile station 260 with closed ramp 270 of FIG. 23 and folding feet (two foots) 350 down. FIG. 29 is a rear perspective view of the mobile station 260 of FIG. 28 . FIG. 30 is a front perspective view of the mobile station 260 of FIG. 29 with ramp 270 closed, handle 280 extended and cooler cover/lid 300 open.
FIG. 31 is a front perspective view with the handle 280 down, cooler lid/cover 300 closed, and ramp 270 down for play. Dashed lines for the handle 280 indicate the ability of the handle to extend and retract. Wheel 340 is shown removed from axle 520 by taking off cap(s) 510 . Each folding foot 350 can be folded up by hinge 530 when the game is ready for play. The removed wheel(s) 340 are useable by the player(s) during the game, while the station 260 is sitting directly on the ground. After playing the game, each front foot 350 can be folded down, the wheels 340 attached to the axles 520 , which allows the station 260 to be easily moved.
FIG. 32 is a front perspective view showing stations 260 set up for play with the wheels 340 removed and each foot folded inside of the lower part of the station 260 . The path 110 of wheel 340 onto the ramp 270 and into the station 260 is shown. FIG. 33 is an enlarged view of the upper corner of the station 260 of FIG. 32 with scoring holes 310 and scoring peg 240 . FIG. 34 is another enlarged view of the upper corner of the station 260 of FIG. 22 with scoring holes 310 and peg 240 moved to a different hole.
Portable Folding Ramp
FIG. 35 is a front perspective view of the portable folding ramp version 390 of the wheels with holes invention. This is very much like the popular game “Corn Hole” in which a bean bag is thrown into a round hole in a similar ramp setup. FIG. 36 is a rear perspective view of the FIG. 35 folding ramp. FIG. 37 is a side view of the FIG. 35 folding ramp version 390 . FIG. 38 is a front view of the FIG. 35 folding ramp 390 . FIG. 39 is top view of the FIG. 35 folding ramp version 390 . FIG. 40 is a back view of the FIG. 35 folding ramp. FIG. 41 is a perspective view of the FIG. 35 folding ramp version 390 . FIG. 42 is a front perspective view of the FIG. 35 folding ramp 400 showing path of a wheel 460 up the ramp 490 trying to aim for track indicia 402 and into the hole 430 .
Referring to FIGS. 35-42 , the folding ramp version can include a main ramp 400 that having track indicia 402 thereon. Ramp 400 hinged at an upper end by a hinge 450 to a hinged support panel 410 , which allows for the ramp 400 to be tilted at different degrees for different levels of play. When not being used, the support panel 410 is folded against ramp 400 allowing ease in transport and reduced space needs for storage.
A hole 420 in the ramp 400 can have a geometrical shape, such as but not limited to a rectangle, a circle, a triangle, and the like. The support panel 410 can have a keyhole shape cut-out 440 which offers extra scoring potential during the game play. Along the edges of the opening 420 can be a ledge 430 which is able to accept inserts that can change the geometry of the opening 440 to add more difficulty during wheel 100 rolling play. The wheel 100 can be rolled along path 460 to the ramp 400 similar to the previous embodiments.
In addition, the ledge 430 around the perimeter of hole 440 can be used to convert the rolling wheel game to the popular corn hole bean bag game. FIG. 43 is an exploded view of the ramp version 390 of FIG. 35 with insert 470 ready for installation into the hole 420 in the ramp 400 . The edges of the insert 470 are sized to fit on the ledge 430 of the hole 420 . FIG. 44 is a perspective view of the FIG. 43 ramp version with insert 470 installed for conversion to Corn Hole play where bean bags can be used instead of wheels. FIG. 45 is a perspective view of the Corn Hole converted ramp 400 showing path 500 of a bean bag 490 into the converted game, where the hole is a bean bag target hole 480 .
The insert 470 can also be used with the slot openings in the previous versions described above, to modify levels of skill and play difficulty.
Descriptions of playing the rolling wheel hole games will now be described.
Official Wheel Hole Playing Rules
2 or 4 players (Can be played with only 1 player for practice or self-challenge)
Wheel Hole's ramps and assemblies can have identical dimensions to insure consistency and fairness. During play, the assemblies should face each other and be separated by the desired distance. The lowest edge of the inclining ramp is also the edge of the perceived foot foul line.
Distance can be measured between foot foul edges of the Wheel Hole ramps.
Pre-measured string or a measuring tape, along with pegs and/or anchors can be used to keep accurate distance between Wheel Holes. Wheels should stay put where they fall.
The following distances in Table 1 can be used for hard surface play such as asphalt, cement or wood:
TABLE 1
DISTANCE
AGE
15 Feet
8-12 years
18 Feet
13 and older
20 Feet
Tournament play
The following distances in Table 2 can be used for average yard surfaces such as grass or dirt.
TABLE 2
DISTANCE
AGE
12 Feet
8-12 years
15 Feet
13 and older
18 Feet
Tournament play
The following distances in Table 3 can be used for play in soft sand or at the beach.
TABLE 3
DISTANCE
AGE
5 Feet
8-12 years
8 Feet
13 and older
10 Feet
Tournament play
In doubles, team partners face can each other from opposite Wheel Hole assemblies.
Each team can play with 2 wheels. If a wheel rolls at least ½ way back, roll it again.
Opponents can alternate turns until all wheels are rolled.
For example, the round is then scores (See Game Scoring Rules). The team with the highest score rolls first. Also, the team that ties the score, rolls first. The winning team rolls first at the starting of the next game. Opponents may call a foot foul and the call must be honored. Alternate rolling sides and R/L positions after each game
Game Scoring Rules:
Winner can be the first player or team to acquire 21 points or more
1 point can be scored for the 1 st wheel rolled into the Wheel Hole target area.
2 points can be scored for the 2 nd wheel rolled in by either team.
3 points can be scored for the 3 rd wheel rolled in by either team.
4 points can be scored for the 4 th wheel rolled in by either team.
5 points can be scored for a wheel rolled through the Wheel Hole at any times, by it doesn't count as a wheel rolled in for added points.
Playing examples will now be described.
Example 1
Red Team rolls first wheel in for 1 point
Blue Team rolls in the next wheel (2 nd ) for 2 points
Red Team misses next roll
Blue Ream rolls in next wheel (3 rd ) for 3 points SCORE: Red Team=1, Blue Team=5
Example 2
Blue Team rolls first, and in for 1 point
Red Team rolls a Wheel Hole through for 5 points
Blue Team rolls next wheel in (2 nd ) for 2 points
Red Team rolls next wheel in (3 rd ) for 3 points
SCORE: Red Team=8, Blue Team=3.
If Example 1 and 2 team SCORES are added together, Red Team=9, Blue Team=8, then the Red Team rolls first, starting the next round. If a foot foul is called on either team, that wheel is disqualified from all scoring.
Game Set-Up
For location, any surface will suffice but a reasonably level playing area should be preferred.
Playing area should be approximately 10 feet wide and 30 feet long. Participants nearest the target Wheel Hole should stop long-rolled wheels with their foot, once they pass the back edge.
If playing in sand, the distance between Wheel Holes should be no more than 10 feet and the forward roll should be used instead of the backspin technique.
The Lingo for the Game
Roller—Players/participants
High Roller(s)—the player or team with the highest or tying score, or winner(s) of the previous game. High Roller would roll first in the next round or to begin the next game.
The Dog House—another name for the target area.
Grey Hound—a wheel rolled too fast and/or too far.
Fender Bender—when the wheel is rolled too hard and bounces back off the target.
Blood Hound—a wheel rolled too slow and/or not far enough which makes it land in . . . .
The Bone Yard—the playing area between both ramps where the wheels fall and stop.
The Bone—any wheel blocking the path of a roller
Lucky Dog—when the wheel comes at least % way back towards the roller. A re-roll is awarded.
The Dog—any wheel, anywhere on the playing surface where it lands.
Run Over the Dog—any wheel that rolls over another wheel on the playing field.
Prairie Dog—when the wheel doesn't go all the way through the cut-out hole in back.
Wheel Hole—when the wheel drops into the target area and totally out of the cut-out.
Wee Ho! Or Wheel Ho!—shouted out when the player rolls a Wheel Hole.
The Stance and Roll
Players can stand upright and behind or to the side of the game assembly when using the back spin roll. Player(s) can also sit on the station boxes during play or at rest. To start, each player can hold the wheel with their thumb and fore-fingers of one hand and loft it with a forward and up flick of the wrist, to within a few feet from the target area, so it lands and rolls forward and straight at a reasonable speed.
To employ the forward roll, players can cup the bottom section of the wheel in your palm, with your fore-fingers extended along the bottom part of the wheel, pointing forward. Players can stand on either side of the Wheel Hold assembly, slightly bent over at the hips to roll and release the wheel low and forward, off your fingers, similar to bowling.
PROGRESSIVE SCORING or UNDERDOG SCORING—favors the person/team with the lower score.
Whether playing singles or doubles, one round is complete after 4 wheels are rolled.
In Singles:
Each player stands behind, or sits on the opponents target. Each player can start with 2 wheels. The first wheel is always rolled by the winner of the previous game or the defending champion. If no prior game was played and there is not a determined champion to roll, a coin toss is appropriate to get started.
Points cam be accumulated by the progression of wheels successfully rolled into either of the Wheel Hole target areas. First wheel in, regardless of who rolls it or which target it is, garners 1 point, second wheel in garners 2 points. Third wheel in garners 3 points and forth wheel in garners 4 points. If a wheel goes all the way through the cut out in the back, 5 points is awarded to that roller but it doesn't count as a wheel in.
Example: players are standing for this example
Player A stands behind Wheel Hole™ station box B. Twenty feet away is Player D standing behind Wheel Hole™ station box C.
Player A|Wheel Hole™ station box B —————— 20 ‘ —————— Wheel Hole™ station box C|Player D Player A rolls first wheel and misses Wheel Hole™ station box C—00 points.
Player D rolls next and the first wheel goes into Wheel Hole™ station box B—01 point (first wheel in).
Player A rolls his/her last wheel into Wheel Hole™ station box C—02 points (second wheel in).
Player D rolls his/her last wheel into Wheel Hole™ station box B—03 points (third wheel in).
*One round of play is complete. Player D has 4 points, player A has 2 points.
Player D rolls first wheel into Wheel Hole™ station box B — 01 point (first in)—now has 5 points total.
Player A rolls next and his/her wheel goes into Wheel Hole™ station box C—02 points (second in) now has 4 points.
Player D rolls his/her last wheel into Wheel Hole™ station box B—03 points (third in)—now has 8 points total.
Player A rolls his/her last wheel into Wheel Hole™ station box C—04 points (4th In)—now has 8 points total.
*Second round is over Player D and Player A are tied at 8 points. Now Player A rolls first in next round.
FIRST one to reach 21 points is the winner of that game regardless of how many wheels remain. The winner then rolls the first wheel to starts the next round.
In Doubles:
Player A & Player E stand behind Wheel Hole™ station box B.
Twenty feet away, Player D and Player F stand behind Wheel Hole™ station box C.
Player A and Player F are partners. Player D and Player E are partners.
Each opposing player standing on one side starts with 2 wheels. The first wheel is always rolled by one of the winners of the previous game or the defending champion team. If no prior game was played and there is no determined champions to roll, a coin toss is appropriate to get started.
The scoring can be accumulated in the same manner as in singles, but the players are rolling towards the same Wheel Hole target taking alternating turns, beginning with the team that has the highest score or the team that has just tied the score. All four wheels can be rolled to end the round. The wheels will then be rolled back in the other direction starting with the team player that has the highest score or just tied the score from the previous round. Continue back and forth until a team reaches 21 points to win.
After a roll, if the wheel rolls back at least half way towards the original roller, he/she gets to roll that wheel again. Otherwise, the wheels can remain where they fall, even if it is blocking the path or ramp. Wheels that are obviously going to miss the target should be stopped by the closest player's foot so the wheel will not keep rolling past.
Degree of Difficulty
Difficulty level can be increased or decreased by changing the distance between Wheel Hole™ station box targets.
*5 point Wheel Hole™ station box (through the back) can be made more easily by changing the width of the cut-out.
The invention components can be formed from various types of materials, such as but not limited to plastic, fiberglass, wood, and the like.
Although the slot described in the back of the box or rear panel is described as keyhole shaped, the slot shape can vary to any geometrical shape or configuration.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended. | Outdoor and indoor rolling games, game box stations ramps and methods of play where one or more participants physically rolls wheels towards a ramp which leads to a box, and a target area, such as circular hole or rectangular hole where player(s) accumulate points under selected playing rules. A station box can have a fold down ramp with an optional opening in the back of the box. Another station can have wheels and cooler in a hand truck arrangement. Another version can use a foldable ramp with removable inserts that allows the game to also be used with bean bags. | 0 |
This application is a 371 of PCT/JP2009/000471 filed Feb. 6, 2009, which application is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fluid reforming device for reforming, as well as tap water, various kinds of fluids (e.g., gray water, sewage water and the like) including heavily contaminated water containing electrolyte substances and organic substances as impurities (e.g., seawater containing water creatures which is used as ballast water for ships; washing water containing bacteria which has been used for washing seafood such as clams; and discharged water containing fats and organic substances included in milk given to calves in farms). More specifically, the invention relates to a fluid reforming device for reforming: tap water such as air-conditioner cooling water (including warm water) circulated in factories; water supplied to boilers, industrial water supplied to factories; drinking water; water used for humidifying room, and the like; gray water (water for flush toilets; renovated industrial waste water; rainwater, and the like); and sewage water such as industrial waste water, river water, and the like; and moreover, bath water of hot springs or 24-hour baths; well water; hard water; soft water; seawater containing sewage which is circulated to be used for aquaculture; and oils to be used repeatedly.
2. Description of Related Art
Cooling water for air conditioners in factories, which is an example of fluids to be reformed, is used in circulation, and dust, dirt, and the like enter the cooling water while it is circulated. Although insoluble dust and dirt are filtered and removed by a filter or the like during circulation, water-soluble substances in the dust or dirt are dissolved into the circulating water. Particularly, substances such as Ca and Mg are oxidized over time, and deposited and accumulated as scales in pipes, which causes clogging of equipment such as pipes and pumps. Further, various kinds of germs (e.g., Escherichia coli, Legionella , and respiratory bacteria that cause pneumonia or bronchitis) also grow in the circulating water. These germs are blown out from an air outlet into room, and cause diseases (diarrhea, stomach ache, and pneumonia). On the other hand, there are problems such as marine pollution caused by ballast water, pollution caused by washing water for seafood, and pollution caused by washing water containing fats and organic substances. The ballast water is seawater used as ballast far ships. Before a ship leaves a port empty; ballast tanks of the ship are filled with seawater at the port. When the ship is loaded with goods at a port of call, an equivalent amount of ballast water is discharged from the ship. The discharged seawater contains sea creatures from the port at which the ship left. Thus, the sea creatures are scattered as invasive species into the sea at the port of call, and adversely affect the ecosystem at the port of call.
Likewise, 24-hour baths or urban hot springs use circulated tap water or hot spring water, respectively, and the water quality is rapidly degraded due to propagation of: minerals that are originally contained in the water (particularly in the hot spring water); electrolytic substances (metal ion such as Na) or organic substances contained in sweat of bathing persons; falling bacteria; and germs discharged from the bathing persons. Likewise, the quality of seawater, which is circulated and used for aquaculture, is also gradually degraded due to wastes of fish kept in a tank, propagating germs, and mixed impurities, which causes a reduction in survival rate of cultured fish.
Reforming of industrial waste water or bath water of a large communal bath has conventionally been performed by adding chemicals (strong disinfectants (oxidizer) such as hypochlorous acid and potassium permanganate) or by using a large-scale aerator. However, these reforming ways have problems such as high cost and need for a large space, and therefore, are not convenient. In particular, it is impossible to add a strong disinfectant (oxidizer) or the like into water circulating in a large bath of an urban hot spring, or water in a home-use 24-hour bath, and it is difficult to introduce a large-scale treatment facility.
A fluid reforming device used for the above-described purposes instead of the large-scale treatment facility has been disclosed in, for example, Japanese Patent Nos. 2623204, 2611080, and 2615308. This device is applicable to the urban hot spring and the home-use 24-hour bath. In the treatment performed by this device, some of the organic compounds in the water are evaporated while the other are deposited, and the supernatant water becomes sterilized clean water, which is verified to be reusable.
BRIEF SUMMARY OF THE INVENTION
However, since this treatment adopts electrolysis in which a constant voltage is applied to AC application electrodes placed in target water, the amount of current that flows in the target water varies depending on the property of the target water. Therefore, it is necessary to perform current setting in accordance with the property of the target water, or change the current setting in accordance with the progress of the treatment. For example, heavily contaminated water contains a large amount of electrolytes, and therefore, allows current to flow easily therein. However, as reforming goes on, the electrolytes decrease and thereby the current becomes less likely to flow. Therefore, the applied voltage must be gradually increased in accordance with the progress of the treatment so that a predetermined amount of current flows constantly. When the target water is hard water, hard water contains a large amount of electrolytes as compared with soft water, and therefore, allows current to flow easily therein. Thus, the amount of current must be adjusted in accordance with the water quality. As described above, since the invention disclosed in the prior arts adopts the constant voltage system, current adjustment in accordance with the target water is required. Apart from a case where there are few construction sites, when many construction sites are established all over the country, current adjustment must be performed in accordance with the installation conditions at the individual construction sites. In this case, the conventional facility takes an extreme amount of time and labor for construction, and therefore, is not suitable for mass production and wide-area construction.
As the electrolysis for improving the water quality is advanced as described above, oxides caused by the electrolysis are gradually deposited on the electrode surface to gradually degrade the current conducting state. Therefore, conventionally, control for keeping the electrode surface clean is performed. However, Ca and Mg, which are main cause of the deposition of oxides, are dissolved in the water, and are gradually accumulated as oxides (scales) in the circulation pipes, resulting in clogging of the pipes and other equipment.
The present invention is made to solve the various problems at once, such as germs, installation sites, and particularly, clogging of pipes and other equipment, and adjustment of installation conditions for mass-production and wide-area installation. The present invention has an object to provide an epoch-making fluid reforming device which requires a small installation site, avoids clogging of pipes, allows uniform on-site adjustment, does not use chemicals or minimizes chemicals if any, enables germ treatment, and purifies and reforms (lowers oxidation-reduction potential) every fluid including water.
A first aspect in accordance with the present invention is directed to Embodiment 1 (refer to FIGS. 1( a ), 1 ( b )) of an electrode block ( 30 ) for fluid reforming, which electrode block ( 30 ) is immersed in a target fluid to be subjected to reforming. The electrode block ( 30 ) includes: (a) a pair or a plurality of pairs of AC application electrodes ( 3 a ) ( 3 b ) which are placed in a target fluid to be subjected to reforming; (b) a ground electrode ( 3 d ) surrounding the AC application electrodes ( 3 a ) ( 3 b ), or placed between the AC application electrodes ( 3 a ) ( 3 b ); (c) a polarity switching circuit ( 2 ) connected to the AC application electrodes ( 3 a ) ( 3 b ), for switching the polarities of the AC application electrodes ( 3 a ) ( 3 b ); and (d) a constant current supply ( 1 ) having a current detector (SR) for detecting current that flows between the AC application electrodes ( 3 a ) ( 3 b ) in fluid reforming, the constant current supply keeping a current value detected by the current detector (SR) constant.
A second aspect in accordance with the present invention is directed to Embodiment 2 (refer to FIGS. 1( c ) and 1 ( d )) of the electrode block ( 30 ). The electrode block ( 30 ) includes: (a) a set of three AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ), the polarities of which are switched so that one of them is a positive electrode, another one is a negative electrode, and the other one is a ground electrode, and at least a set of three AC application electrodes being placed in a target fluid to be subjected to reforming; (b) a ground electrode ( 3 d ) surrounding the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ), or placed inside the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ); (c) a polarity switching circuit ( 2 ) connected to the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ), for switching the polarities of the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ); and (d) a constant current supply ( 1 ) having a current detector (SR) for detecting current that flows between the electrodes in fluid reforming, the constant current supply keeping a current value detected by the current detector (SR) constant.
A case where the electrode block ( 30 ) according to Embodiment 1 or 2 is placed in a container ( 10 ) for fluid reforming (refer to FIGS. 2 to 11 ), the electrode block ( 30 ) may be placed in the container ( 10 ) for fluid reforming which has an inlet ( 14 ) for introducing an unpurified fluid and an outlet ( 15 ) for discharging a purified fluid.
In the Embodiment 2, a set of three AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ), each being bent in a V shape, may be arranged on a concentric circle, symmetrically with respect to a point. By successively selecting adjacent two of the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) and turning on the selected electrodes, the surfaces of the electrodes are kept clean, and thus electrolysis performance can be maintained for a long time.
The electrodes ( 3 a ) ( 3 b ) ( 3 c ) ( 3 d ) may be formed of a porous material. Therefore, circulation of the fluid in the container ( 10 ) is smoothly carried out, and contact of the fluid to the electrodes ( 3 a ) ( 3 b ) ( 3 c ) ( 3 d ) is smoothly carried out. Thus, high electrolysis performance can be maintained.
According to the electrode block ( 30 ) of the present invention, which is disclosed in claim 1 or claim 2 , a flowing target fluid (in claim 3 , a target fluid that flows in the container ( 10 )) or a target fluid stored in the batch type container ( 10 ) (refer to FIG. 6 ) contacts the AC application electrodes ( 3 a ) ( 3 b ), or ( 3 b ) ( 3 c ), or ( 3 c ) ( 3 a ), which are non-ground electrodes, and is subjected to electrolysis. Then, electrolyte impurities (mostly Ca, also Mg and Si) dissolved in the fluid are oxidized in the fluid as described later, and the oxides of the electrolyte impurities are deposited and accumulated on the surface of the ground electrode ( 3 d ). Thereby, deposition of electrolyte impurities in pipes, which have been dissolved in the circulating fluid such as air conditioner cooling water, is significantly reduced, and clogging of the pipes is resolved or significantly retarded. Also in the case of the batch type container ( 10 ), deposition of electrolyte impurities on the inner wall and the like of the body ( 11 ) is reduced. The ground electrode ( 3 d ) is replaced depending on the degree of contamination at the surface thereof.
The above-described electrolysis lowers the oxidation-reduction potential of the target fluid. However, active oxygen and active hydrogen caused by the electrolysis are partially dissolved in the target fluid, and the dissolved oxygen in the target fluid promotes oxidizing reaction of electrolyte impurities and organic substances (including germs) in the target fluid to detoxify them.
On the other hand, the active hydrogen in the target fluid dissolves sticky and gooey organic substances (proteolipid) attached to the surface and corners (particularly, the corners at the bottom where the target fluid is not circulated) of the body ( 11 ) of the container ( 10 ), and thereby keeps the inside of the container ( 10 ) clean. When the sticky organic substances are dissolved and removed, germs (particularly, Legionella ) hidden in and behind the organic substances are dissolved and killed by the dissolved active oxygen.
In the present invention, since the current that flows between the AC application electrodes during fluid reforming is kept constant, the type of the target fluid is not limited. That is, a heavily contaminated fluid (i.e., contaminated water) or hard water containing a large amount of impurities or minerals, respectively, and therefore, efficiently conducts electricity and allows electrolysis to advance. When the purity of such target fluid is increased with the advance of electrolysis, the target fluid becomes less likely to conduct electricity and slows the electrolysis. By keeping the current constant, purification is performed by constant electrolysis regardless of the type of the target fluid. Accordingly, in contrast to the conventional art, the present invention does not require current adjustment for each installation site, and therefore, has an advantage in mass production and wide-area installation. In addition, since impurities (mostly Ca) in the fluid are deposited and accumulated on the ground electrode and removed, the impurities are prevented from depositing in equipment such as pipes and pumps, or containers. Furthermore, hazardous organics such as germs in various polluted water, contaminated water, ballast water and the like can be removed by the fluid reforming with electrolysis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating a case where the device of the present invention is applied to an aquaculture pond or the like.
FIG. 2 is a schematic diagram illustrating a case where the device of the present invention is applied to industrial wastewater treatment or the like.
FIG. 3 is a schematic diagram illustrating a case where the device of the present invention is applied to a cooling water piping system for air conditioning; or the like.
FIG. 4 is a schematic diagram illustrating a ease where the device of the present invention is applied to a 24-hour bath or the like.
FIG. 5 is a cross-sectional view of a container for continuous treatment according to the first embodiment of the present invention.
FIG. 6 is a cross-sectional view of a batch type container according to the first embodiment of the present invention.
FIG. 7 is a cross-sectional view illustrating an example of the device of the present invention, which uses parallel plate-shaped electrodes.
FIG. 8 is a cross-sectional view of FIG. 7 .
FIG. 9 is a cross-sectional view of a pipe connection type container of the device of the present invention.
FIG. 10 is a partially exploded perspective view according to the second embodiment of the present invention.
FIG. 11 is a cross-sectional view of FIG. 10 .
FIG. 12 is a block diagram illustrating the first embodiment of the present invention.
FIG. 13 is a block diagram illustrating the second embodiment of the present invention.
FIG. 14 is a block diagram illustrating a modification of the second embodiment of the present invention.
FIG. 15 is a block diagram illustrating a constant current supply of the device of the present invention.
REFERENCE SIGNS LIST
( 1 ) constant current supply
( 2 ) switching circuit
( 3 a ), ( 3 b ), ( 3 c ) AC application electrodes
( 3 d ) ground electrode
( 10 ) container
( 14 ) inlet
( 15 ) outlet
( 51 ) outgoing circulation pipe
( 52 ) returning circulation pipe
( 60 ) boiler
( 70 ) bathtub
( 80 ) heat exchanger
(SR) current detector
DESCRIPTION OF EMBODIMENTS
The present invention will be described by way of embodiments with reference to the drawings. FIG. 1 illustrates a case where fluid reforming is performed with an electrode block ( 30 ) of the present invention being directly placed in a target fluid. FIGS. 2 to 4 illustrate examples of installation of a fluid reforming device having the electrode block ( 30 ) of the present invention. In the case of FIG. 1 , the target fluid is stored in a concave place ( 70 ) such as: an aquaculture pond; a water tank such as a lower tank or a water receiving tank of a cooling tower; a ballast tank of a ship; or a milk fat separation tank, and only the electrode block ( 30 ) of the present invention is immersed in the target fluid to purify and reform the target fluid. In the ease of FIG. 2 , industrial waste water, lap water, well water, or gray water, which is a target fluid from a water source ( 70 ), is reformed, and the reformed clean water is supplied or discharged as it is. A fluid reforming device (A) is placed between pipes ( 51 ) ( 52 ). A high-frequency AC voltage generated by an AC generator ( 90 ) is applied to electrodes in a fluid-purifying container ( 10 ), and thereby a constant current flows in the target fluid. FIG. 3 illustrates, representatively, a circulation piping system for air conditioning, in which water is circulating between an air conditioner ( 70 ) and a cooling tower (or chiller) ( 60 ) installed outdoor, and the fluid reforming device (A) of the present invention is placed in middle of a pipe ( 52 ) connecting the air conditioner and the cooling tower. Alternatively, a combination of a bathtub ( 70 ) and a boiler ( 60 ) as a heat source is also considered. FIG. 4 illustrates an example of a 24-hour bath or an urban hot spring, in which hot water in the bathtub ( 70 ) and boiling water heated by the boiler ( 60 ) exchange heat via a heat exchanger ( 80 ), and the fluid reforming device (A) of the present invention is placed in the middle of a pipe ( 52 ) of the bathtub ( 70 ). Reference numeral ( 53 ) denotes a boiler pipe. In the cases shown in FIGS. 2 and 3 , only the electrode block ( 30 ) shown in FIG. 1 may be used.
Hereinafter, the present invention will be described with reference to a cooling water circulation system for air conditioning in a factory, which is a representative example of the present invention, shown in FIG. 3 . FIG. 7 is a cross-sectional view of a container ( 10 ) of the fluid reforming device (A) of the present invention. Any of various electrode blocks ( 30 ) of the present invention, which are described in this specification, is stored in the container ( 10 ). The container ( 10 ) is composed of a cylindrical body ( 11 ), a semispherical bottom section ( 13 ) provided at a bottom of the body ( 11 ), and an upper lid ( 12 ). A flange ( 11 a ) is provided at an outer periphery of an upper opening of the body ( 11 ), and an outer peripheral part of the upper lid ( 12 ) is bolted to the flange ( 11 a ). A pipe-shaped inlet ( 14 ), which is communicated with the inside of the body ( 11 ), is provided on an upper side surface of the body ( 11 ), and a pipe-shaped outlet ( 15 ), which is communicated with the inside of the body ( 11 ), is provided on a lower side surface of the body ( 11 ) at the opposite side from the inlet ( 14 ). Examples of materials of the fluid purifying container ( 10 ) are, but not limited to, resins, ceramics, metals (including stainless) and the like. Most suitable one is used depending on the purpose. The fluid purifying container ( 10 ) made of stainless will be described as a representative example.
A drain pipe ( 17 ) is connected, via a drain valve ( 17 a ), to a central lowermost part of the bottom section ( 13 ) extending from the body ( 11 ), and sediments (mostly oxides of Ca, Mg, and Si, or other solids) deposited in the bottom section ( 13 ) are timely discharged through the drain valve ( 17 a ). Electrode support frames ( 19 ) are arranged in the middle stage in the container ( 10 ) so as to intersect with each other across the body ( 11 ), and the ends of the frames ( 19 ) are welded to an inner circumference surface of the container ( 10 ). Further, the bottom section ( 13 ) of the container ( 10 ) is fixed on support legs ( 16 ).
The simplest structure of electrodes of the present invention is shown in FIGS. 5 and 12 . The electrode block ( 30 ) of the fluid reforming device of the present invention comprises: a pair of upper and lower resin rings ( 35 ) ( 36 ), each having a diameter slightly smaller than that of the container ( 10 ) and formed of a chemically nonreactive stable resin such as tetrafluoroethylene; a cylindrical ground electrode ( 3 d ) having the resin rings ( 35 ) ( 36 ) on its upper and lower ends, respectively; a pair of plate-shaped AC application electrodes ( 3 a ) ( 3 b ) which are arranged in parallel and opposed to each other in the cylindrical ground electrode ( 3 d ) (a plurality of pairs of AC application electrodes ( 3 a ) ( 3 b ) may be arranged); and a lid ( 35 a ) which is detachably fitted into the upper resin ring ( 35 ). Conductive wires ( 31 a ) ( 31 b ) ( 31 d ) are connected to the AC application electrodes ( 3 a ) ( 3 b ) and the cylindrical ground electrode ( 3 d ), respectively, and the conductive wires ( 31 a ) ( 31 b ) penetrate through the lid ( 35 a ). In FIG. 6 , the conductive wires ( 31 a ) ( 31 b ) are provided inside the lid ( 12 ). In FIG. 5 , fixing members ( 37 ) ( 38 ) for fixing the AC application electrodes ( 3 a ) ( 3 b ) are arranged on the upper and lower resin rings ( 35 ) ( 36 ), respectively, and thereby the AC application electrodes ( 3 a ) ( 3 b ) are fixed.
The electrodes ( 3 a ) ( 3 b ) ( 3 d ) [also electrodes ( 3 a ) ( 3 b ) ( 3 c ) ( 3 d ) described later] are each formed of a porous material such as a metal mesh, a perforated metal, or a metal lath, or a flat plate. In particular, the AC application electrodes ( 3 a ) ( 3 b ) [also AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) described later] are platinum plated. On either of the facing surfaces of the AC application electrodes ( 3 a ) ( 3 b ) [also AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) described later], a rectangle thick Mg block ( 40 ) is fixed through a fixing member ( 41 ) made of a chemically nonreactive stable resin such as tetrafluoroethylene. An example of a method for fixing the Mg block ( 40 ) is as follows. As shown in an enlarged view (i) in a circle in FIG. 5 , an end of the Mg block ( 40 ) is fitted into a groove ( 41 a ) formed in the fixing member ( 41 ), and the Mg block ( 40 ) is fixed with a screw ( 41 d ) in a state where the Mg block ( 40 ) is insulated from the electrode ( 3 a ) [or ( 3 b ), ( 3 c )] by an insulating pipe ( 41 c ). Another fixing method is shown in an enlarged view (ii). The Mg block ( 40 ) is provided between fixing members ( 41 i ) ( 41 ii ) made of a chemically nonreactive stable resin such as tetrafluoroethylene, and the Mg block ( 40 ) is fixed by a screw ( 41 d ) in a state where the Mg block ( 40 ) is insulated from the electrode ( 3 a ) [or ( 3 b ), ( 3 c )] by an insulating pipe ( 41 c ) as described above. When the amount of electrolytes dissolved in the target fluid is insufficient, the Mg block ( 40 ) dissolves in the target fluid to promote initial electrolysis. As a material of the ground electrode ( 3 d ), titanium or stainless (for example, a plate, a perforated metal, or a porous plate) is used to avoid electric corrosion. The electrode block ( 30 ) thus constructed is placed on the electrode support frames ( 19 ) in the container ( 10 ).
As shown in FIG. 12 , the AC application electrodes ( 3 a ) ( 3 b ) [also AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) described later] are connected to a polarity switching circuit ( 2 ), while the ground electrode ( 3 d ) is grounded (GND).
FIG. 12 shows an example of a specific control circuit for the AC generator ( 90 ) according to Embodiment 1 shown in FIG. 5 . FIG. 15 shows an example of a constant current supply ( 1 ) of the control circuit. Firstly, the control circuit shown in FIG. 12 will be described. The control circuit shown in FIG. 12 comprises an oscillation circuit ( 6 ), a frequency divider ( 5 ), an operation setting circuit ( 4 ), gate driving circuits ( 7 a ) ( 7 b ), a polarity switching circuit ( 2 ), and a constant current supply ( 1 ). The oscillation circuit ( 6 ) and the operation setting circuit ( 4 ) are connected to the frequency divider ( 5 ). The frequency divider ( 5 ) is connected to gates of switching elements (W 1 ) to (W 4 ) of the polarity switching circuit ( 2 ) via a pair of gate driving circuits ( 7 a ) ( 7 b ). Each of the switching elements (W 1 ) to (W 4 ) is implemented by an FET in which a current flows between a drain and a source when the gate potential is higher than the source potential.
Two of the switching elements (W 1 ) to (W 4 ), such as (W 1 ) (W 2 ) or (W 3 ) (W 4 ), are connected in series to form a pair of switching circuit section ( 2 a ) or ( 2 b ), respectively. The two pairs of switching circuit sections ( 2 a ) ( 2 b ) are connected in parallel to constitute the polarity switching circuit ( 2 ) [=FET bridge circuit]. Specifically, the sources of the switching elements (W 1 ) (W 3 ) are connected to the drains of the switching elements (W 2 ) (W 4 ) to form the switching circuit sections ( 2 a ) ( 2 b ). The drains of the switching elements (W 1 ) (W 3 ) of the switching circuit sections ( 2 a ) ( 2 b ) are connected to each other, and the sources of the switching elements (W 2 ) (W 4 ) are connected to each other. The gates of the switching elements (W 1 ) to (W 4 ) are connected to the gate driving circuits ( 7 a ) ( 7 b ).
The conductive wires ( 31 a ) ( 31 b ) extending from a connection point (P 1 ) of the switching element (W 1 ) (W 2 ) and a connection point (P 2 ) of the switching elements (W 3 ) (W 4 ) are connected to the AC application electrodes ( 3 a ) ( 3 b ), respectively. The positive terminal (+) of the DC constant current source ( 1 ) is connected to the drains of the switching elements (W 1 ) (W 3 ), while the negative terminal (−) thereof is connected to the sources of the switching elements (W 2 ) (W 4 ) and to the ground electrode ( 3 d ), and further, grounded (GND) through the conductive wire ( 31 d ).
In the present embodiment, the oscillation circuit ( 6 ) is implemented by a crystal oscillator having a frequency of 1.308 MHz (the frequency of the crystal oscillator is not limited thereto). A pulse generated by the oscillation circuit ( 6 ) is frequency-divided by the frequency divider ( 5 ) connected to the oscillation circuit ( 6 ) to synthesize a signal for the gate driving circuits. The conditions for frequency division depend on the setting by the operation setting circuit ( 4 ) described below.
The operation setting circuit ( 4 ) determines circuit operation setting in accordance with the electrode specification. A mode corresponding to the two-electrode two-phase driving system ( FIG. 12 ) or a mode corresponding to the three-electrode three-phase driving system ( FIG. 13 or 14 ) is designated by using an operation switch, thereby setting the operation of the frequency divider ( 5 ). Specifically, the crest values, wave numbers, and duty ratios (symmetric or asymmetric) at the positive side and the negative side of the AC waveform applied to the electrodes ( 3 a ) ( 3 b ) or the electrodes ( 3 a ) ( 3 b ) ( 3 c ) are designated. In the present embodiment, the crest values, wave numbers, and duty ratios (symmetric or asymmetric) at the positive side and the negative side of the AC waveform are symmetric, but the present invention is not limited thereto.
The frequency divider ( 5 ) receives the pulse from the oscillation circuit ( 6 ) as a reference signal, and frequency-divides the pulse in accordance with the signal from the operation setting circuit ( 4 ) to generate a pulse signal for the gate driving circuits. Specifically, firstly, the frequency divider ( 5 ) frequency-divides the reference signal from the oscillation circuit ( 6 ) on the basis of an operation mode instruction from the operation setting circuit ( 4 ) to generate a required timing pulse. The polarity conversion period (the positive/negative switching period) and the pulse width (the current flowing time) of the electrodes ( 3 a ) ( 3 b ) [or the electrodes ( 3 a ) ( 3 b ) ( 3 c ) in the case of three-electrode driving described later] can be changed by changing the frequency division ratio. In the embodiment shown in FIG. 5 , since the two-electrode two-phase driving system is adopted, mutually inverted pulses are supplied to the gate driving circuits ( 7 a ) ( 7 b ), respectively. In the three-electrode three-phase driving system using the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) described later, 120° phase-shifted pulses are supplied to the gate driving circuits ( 7 a ) ( 7 b ) ( 7 c ), respectively. The amount of phase shift is not limited to 120°. The same effect can be achieved by the phase shift. This point is common throughout the description.
The gate driving circuits ( 7 a ) ( 7 b ) convert the signals from the frequency divider ( 5 ) to gate signals for the switching elements (W 1 ) (W 2 ) of the switching circuit section ( 2 a ) and the switching elements (W 3 ) (W 4 ) of the switching circuit section ( 2 b ), respectively. In the case of the two-electrode two-phase driving system, 180° inverted two pulses are generated and outputted at a predetermined timing to the gates of the switching elements (W 1 ) (W 2 ) of the switching circuit section ( 2 a ) and the gates of the switching elements (W 3 ) (W 4 ) of the switching circuit section ( 2 b ), respectively. The inverted pulses are not limited to 180° inverted pulses. The same effect can be achieved also by the phase shift. This point is common throughout the description.
The constant current supply ( 1 ) is illustrated in FIG. 15 . Specifically, the constant current supply ( 1 ) comprises: a rectifier circuit ( 1 a ) having a diode bridge structure, which is connected to a commercial power supply (S); a transformer (T 1 ) having one terminal on the primary side, which is connected to an output terminal of the rectifier circuit ( 1 a ); a chopping element (Tr 1 ) having a collector connected to the other terminal of the transformer (T 1 ), and an emitter connected to an input terminal of the rectifier circuit ( 1 a ); a capacitor (C 1 ) provided between the output terminal and the input terminal of the rectifier circuit ( 1 a ); a driver circuit (DV) for driving the chopping element (Tr 1 ), which is connected to a base of the chopping element (Tr 1 ); a pulse width control circuit (PWC) for chopping-controlling the driver circuit (DV); a smoothing circuit (H 1 ) composed of a diode (Do 1 ) provided on the positive (+) line side on the secondary side of the transformer (T 1 ), and a smoothing capacitor (C 2 ) provided between the positive (+) and negative (−) lines on the secondary side; voltage-division resistors (R 1 ) (R 2 ) provided between the positive (+) and negative (−) lines on the secondary side; a voltage control comparator (OP 2 ) having an input terminal connected to a connection point (P 3 ) of the voltage-division resistors (R 1 ) (R 2 ); and an applied voltage reference potential output section (V 2 ) connected to a reference potential input terminal as another input terminal of the voltage control comparator (OP 2 ). An output terminal of the voltage control comparator (OP 2 ) is connected to the pulse width control circuit (PWC). The applied voltage reference potential output section (V 2 ) is implemented by a variable resistor so that the maximum voltage applied to the electrodes ( 3 a ) ( 3 b ) [or the electrodes ( 3 a ) ( 3 b ) ( 3 c ) described later] can be controlled according to need.
An output voltage from a current detector (SR) is connected to an input terminal of a current control comparator (OP 1 ) via an amplifier (Z 1 ), and a current control reference potential output section (V 1 ) is connected to a reference potential input terminal as another input terminal of the current control comparator (OP 1 ). The output terminal of the current control comparator (OP 1 ) is also connected to the pulse width control circuit (PWC). The current control reference potential output section (V 1 ) is also implemented by a variable resistor so that the reference voltage (i.e., the inter-electrode current) can be controlled according to need. The reference potential output sections (V 1 ) (V 2 ) are included in the operation setting circuit ( 4 ), and an operator is allowed to operate the same according to need. The input and output terminals (−) and (+) of the constant current supply ( 1 ) are connected to the polarity conversion switching circuit ( 2 ), and a predetermined constant current is constantly supplied to the electrodes ( 3 a ) ( 3 b ) [or the electrodes ( 3 a ) ( 3 b ) ( 3 c ) described later]. In the embodiment shown in FIG. 12 , the constant current is supplied to the electrodes ( 3 a ) ( 3 b ). In the three-electrode system shown in FIG. 1 , the constant current is supplied to the electrodes ( 3 a ) ( 3 b ) ( 3 c ).
Next, the function of the embodiment shown in FIG. 5 (two-electrode system) will be described, taking a cooling water piping system for air conditioning in FIG. 3 as an example. The embodiment shown in FIG. 8 (three-electrode system), which is similarly applicable, will be described later. The container ( 10 ) is attached to the pipe ( 52 ) connecting the air conditioner ( 70 ) and the cooling tower ( 60 ). Water flows in the body ( 11 ) as the container body. When the fluid reforming device is turned on, gate driving signals, which are 180° phase-shifted from each other, are output from the frequency divider ( 5 ) to the gate driving circuits ( 7 a ) ( 7 b ) in a period set by the operation setting circuit ( 4 ). That is, when a gate driving signal is input to the gate driving circuit ( 7 a ), a signal is output from the gate driving circuit ( 7 a ) to the gate of the switching element (W 1 ), and thereby the switching element (W 1 ) is turned on. Since no signal is output to the other switching element (W 2 ) which is paired with the switching element (W 1 ); the switching element (W 2 ) remains off. As a result, current flows from the switching element (W 1 ) through the connection point (P 1 ) to the electrode ( 3 a ).
A gate driving signal, which is 180° phase-shifted, is sent to the other gate driving circuit ( 7 a ), and a signal is sent to the gate of the switching element (W 4 ) to turn on the switching element (W 4 ). Since no signal is sent to the switching element (W 3 ) which is paired with the switching element (W 4 ), the switching element (W 3 ) remains off. As a result, current flows from the electrode ( 3 a ) to the electrode ( 3 b ) and passes through the connection point (P 2 ) and the switching element (W 4 ) to return to the minus terminal of the constant current supply ( 1 ).
Since the ground electrode ( 3 d ), which is arranged surrounding the electrodes ( 3 a ) ( 3 b ), is always grounded and the negative electrode ( 3 b ) is also grounded, these electrodes ( 3 d ) ( 3 b ) are of the same potential, and current also flows from the positive electrode ( 3 a ) to the ground electrode ( 3 d ). This state continues for a period of time that is set on a timer (T) of the operation setting circuit ( 4 ). When the set time has passed, the signals sent from the gate driving circuits ( 7 a ) ( 7 b ) to the switching elements (W 1 ) to (W 4 ) are inverted, and thereby the current flowing direction is reversed. That is, the signal from the gate driving circuit ( 7 b ) is not input to the switching element (W 4 ) but is input to the switching element (W 3 ). Then, the current from the constant current supply ( 1 ) flows from the switching element (W 3 ) through the connection point (P 2 ) to the electrode ( 3 b → 3 a ) whose polarity has just been changed from negative to positive. On the other hand, the signal from the gate driving circuit ( 7 a ) is input to the switching element (W 2 ) but is not input to the switching element (W 1 ). As a result, the electrode ( 3 a ) whose polarity has just been positive is changed to a negative electrode, and current flows from the electrode ( 3 b → 3 a ) to the electrode ( 3 a → 3 b ) and passes through the connection point (P 1 ) and the switching element (W 2 ) to return to the constant current supply ( 1 ). Further, as described above, a portion of the current from the electrode ( 3 b → 3 a ) also flows to the ground electrode ( 3 d ). Thus, polarity switching between the electrodes ( 3 a ) ( 3 b ) is performed in accordance with the polarity switching period of the operation setting circuit ( 4 ), and thereby electrolysis of the fluid is performed.
The electrolysis causes the electrolytes in the fluid to be deposited on the negative (−) side electrode and the ground electrode ( 3 d ). However, since the polarities of the electrodes ( 3 a ) ( 3 b ) are switched at high speed, the deposits on the surface of each electrode break away when the polarity of the electrode is changed to positive. As a result, the electrolytes are not deposited on the electrodes ( 3 a ) ( 3 b ) but are deposited on the ground electrode ( 3 d ). Accordingly, it is possible to continue the electrolysis over a long time until the deposits finally cause the current not to flow toward the ground electrode ( 3 d ). When a predetermined amount of deposits are accumulated on the ground electrode ( 3 d ), the fluid reforming device is turned off to replace the ground electrode ( 3 d ).
As described above, a fluid containing electrolytes is subjected to electrolysis. However, the amount of electrolytes varies from fluid to fluid, or the amount of electrolytes decreases with the advance of electrolysis and thereby the amount of current flowing in the fluid varies. Such variation in the amount of current considerably affects mass production and wide-area installation of the fluid reforming device of the present invention, as described above. So, in the constant current supply ( 1 ), the current detector (SR) detects the amount of current that flows between the electrodes ( 3 a ) ( 3 b ) to keep the current constant.
That is, the current that flows between the electrodes ( 3 a ) ( 3 b ) is detected by the current detector (SR). When the current flowing between the electrodes ( 3 a ) ( 3 b ) flows into the current detector (SR) which is implemented by a resistor, a voltage (referred to as a sense voltage, hereinafter) is generated. The sense voltage is amplified by an amplifier (Z 1 ) [not required if the sense voltage is sufficiently high], and then input to the input terminal of the current control comparator (OP 1 ) to be compared with the voltage of the current control reference voltage output section (V 1 ). When these voltages are of the same potential, it means that the amount of current set by the operation setting circuit ( 4 ) flows between the electrodes ( 3 a ) ( 3 b ).
However, if the potential supplied from the current detector (SR) to the input terminal of the current control comparator (OP 1 ) is lower than the potential of the current control reference voltage output section (V 1 ), it is determined that the amount of current that flows between the electrodes ( 3 a ) ( 3 b ) is smaller than the amount of current that is set by the operation setting circuit ( 4 ). Then, a current increasing signal is supplied from the output terminal of the current control comparator (OP 1 ) to the pulse width control circuit (PWC).
On receipt of this signal, the pulse width control circuit (PWC) instructs the driver circuit (DV) to increase its pulse width so as to extend the ON time of the chopping element (Tr 1 ). Thereby, the ON time of the chopping element (Tr 1 ) is extended, and the current that flows on the primary side of the transformer (T 1 ) increases. With the increase in the current that flows on the primary side of the transformer (T 1 ), the current that flows on the secondary side of the transformer (T 1 ) also increases in proportion thereto. The current increasing operation is performed until reaching the reference potential of the current control reference voltage output section (V 1 ).
When the fluid flows in the container ( 10 ) at a constant speed, the amount of electrolytes does not vary significantly. However, when the fluid in the container ( 10 ) does not flow because the container ( 10 ) is of the batch type, the amount of electrolytes decreases and the current becomes less likely to flow with the advance of electrolysis, and thereby the potential on the secondary side of the transformer (T 1 ) gradually increases. Assuming that the potential on the secondary side of the transformer (T 1 ) is (Vcc), a divided voltage (Vs) applied to the voltage control input terminal of the voltage control comparator (OP 2 ) is [Vcc×R 2 /(R 1 +R 2 )], and compared with the reference voltage of the applied voltage reference potential output section (V 2 ). A voltage increasing signal is transmitted to the pulse width control circuit (PWC) until the voltage (Vs) applied to the voltage control input terminal becomes equal to the reference voltage of the applied voltage reference potential output section (V 2 ) so as to increase the current flow. However, the voltage (Vs) applied to the voltage control input terminal cannot exceed the reference voltage of the applied voltage reference potential output section (V 2 ).
Conversely, if the fluid contains an excessive amount of electrolytes, excess current flows between the electrodes ( 3 a ) ( 3 b ). Then, the voltage supplied from the current detector (SR) to the input terminal of the current control comparator (OP 1 ) becomes higher than the potential of the current control reference voltage output section (V 1 ), and a current decreasing signal is output from the current control comparator (OP 1 ) to the pulse width control circuit (PWC).
On receipt of the current decreasing signal, the pulse width control circuit (PWC) instructs the driver circuit (DV) to shorten its pulse width so as to reduce the ON time of the chopping element (Tr 1 ). Thereby, the ON time of the chopping element (Tr 1 ) is reduced, and the current that flows on the primary side of the transformer (T 1 ) decreases. With the decrease in the current that flows on the primary side of the transformer (T 1 ), the current that flows on the secondary side of the transformer (T 1 ) also decreases in proportion thereto. The current decreasing operation is performed until reaching the reference potential of the current control reference voltage output section (V 1 ). Simultaneously, the potential on the secondary side of the transformer (T 1 ) is gradually lowered with the current decreasing operation, and a voltage decreasing signal is transmitted to the pulse width control circuit (PWC) to make the current less likely to flow.
As described above, the fluid is reformed by electrolysis, that is, the electrolyte impurities contained in the fluid are caused to deposit on the ground electrode ( 3 d ) to prevent the electrolyte impurities from depositing in the pipes through which the fluid is circulated. Since the electrolysis is performed under constant current control, the current that flows between the electrodes ( 3 a ) ( 3 b ) is constant even when the amount of electrolytes contained in the fluid is excessively large or small, or varies. Therefore, any fluid (seawater or oil as well as water) can be treated with a single current setting, and a fluid reforming device can be used in factory sites across the country. Moreover, in parallel with the fluid reforming by electrolysis, impurities in the fluid can be deposited and accumulated on the ground electrode and removed. Therefore, clogging of the pipe system is avoided or significantly reduced, and thus the maintainability can be significantly enhanced.
As described above, FIG. 1 shows the case where only the electrode block ( 30 ) is immersed in the fluid stored in the aquaculture pond ( 70 ) or the lower tank ( 70 ) of the cooling tower. In the electrode block ( 30 ), the AC application electrodes ( 3 a ) ( 3 b ) [or the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c )] and the ground electrode ( 3 d ) are arranged. In the former case, the ground electrode ( 3 d ) is placed between the AC application electrodes ( 3 a ) ( 3 b ), and impurities are deposited and accumulated on the ground electrode ( 3 d ). So, the ground electrode ( 3 d ) should be replaced. In the latter case using the multiple electrodes ( 3 a ) ( 3 b ) ( 3 c ), the ground electrode ( 3 ) is a porous cylindrical body surrounding the electrodes, or a porous cylindrical body placed so as to be surrounded by the electrodes. The ground electrode ( 3 ) is not limited to the porous cylindrical body, but may be a solid body or a plate. In FIG. 1 , a diagram on the right side, which is enclosed in a circle, shows the case where a porous cylindrical body is used. The driving system using the electrodes ( 3 a ) ( 3 b ) ( 3 c ) will be described later. The two-electrode driving system is as described above. In this case, part (c) in the circle of FIG. 1 shows a member (K) surrounding the electrodes ( 3 a ) ( 3 b ) ( 3 c ). Of course, in the case of using the multiple electrodes ( 3 a ) ( 3 b ) ( 3 c ), the member surrounding the electrodes ( 3 a ) ( 3 b ) ( 3 c ) is the ground electrode ( 3 d ). Accordingly, in the latter case, the character in part ( c ) of FIG. 1 is not (K) but ( 3 d ).
FIG. 2 shows a case where the fluid reforming device is used for purifying industrial waste water, ballast seawater, sewage water used for washing seafood, sewage water containing fat, or the like, in which the electrode block ( 30 ) is installed according to the purpose as shown in FIGS. 7 to 9 . The type of the electrode block ( 30 ) to be used is shown in FIG. 1 . FIG. 4 shows a case of an urban hot spring or a 24-hour bath, in which a bathtub ( 70 ) and a boiler ( 60 ) are connected via a heat exchanger ( 80 ).
FIG. 6 shows a case where a target fluid is purified in a batch type fluid reforming device, and the device is used as a home-use water purifier, for example. FIG. 6 is structurally identical to FIG. 5 . The AC application electrodes ( 3 a ) ( 3 b ) [or the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) which are not shown] are supported in the lid ( 12 ). A support rod ( 12 a ) hangs down from the center of the lid ( 12 ), and an earth bar ( 39 a ) is provided at a lower end of the support rod ( 12 a ) and connected to the cylindrical ground electrode ( 3 d ). The earth bar ( 39 a ) is screwed to the lower end of the support rod ( 12 a ) together with the lower ground electrode ( 3 d 1 ) which is fitted in the lower resin ring ( 36 ).
Next, the case of using multiple electrodes will be described with reference to FIGS. 8 to 11 . The same components as those of Embodiment 1 are designated by the same reference characters, and the description thereof will be omitted. FIGS. 10 and 11 show an example where a set of V-shaped AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) are arranged in the cylindrical ground electrode ( 3 d ), and FIG. 8 shows another example in which parallel plate electrodes ( 3 a ) ( 3 b ) ( 3 c ) are used. The structure shown in FIG. 8 is, assuming that the center electrode is the ground electrode ( 3 d ), a two-electrode two-phase driving system which uses the cylindrical ground electrode ( 3 d ) and the center plate ground electrode ( 3 d ).
Hereinafter, some embodiments are explained with FIGS. 8 , 10 , 11 , and 13 . As described above, FIG. 8 shows an example using parallel plate electrodes ( 3 a ) ( 3 b ) ( 3 c ), and FIGS. 10 and 11 show an example using V-shaped electrodes ( 3 a ) ( 3 b ) ( 3 c ). In Embodiment 2, a set of three AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) are used, and the polarities of the AC application electrodes are switched so that one of them is a positive electrode, another one is a negative electrode, and the other one is a ground electrode. These AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) are placed inside the cylindrical ground electrode ( 3 d ). In this case, three gate driving circuits ( 7 a ) ( 7 b ) ( 7 c ) lead from the frequency divider ( 5 ) to the corresponding AC application electrodes ( 3 a ) ( 3 b ) ( 3 b ), and are connected to the gates of switching elements (W 1 ) to (W 6 ) in a polarity switching circuit ( 2 ) for switching the polarities of the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ). Then, gate driving signals, which are 120° shifted from each other, are output from the frequency divider ( 5 ) to the gate driving circuits ( 7 a ) ( 7 b ) ( 7 c ). Thereby, as described in Embodiment 1, two of the three AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) are paired and supplied with AC at a timing set by the timer (T), while the remaining one electrode is grounded. In this way, the two electrodes to be paired, among the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ), are successively changed at the predetermined timing, the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) are always kept clean, and impurities are deposited and accumulated on the constantly-grounded ground electrode ( 3 d ). Thus, clogging of pipes due to deposition and accumulation of impurities can be avoided.
In the case of FIGS. 10 and 11 , the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) are each formed by bending, in a V shape in a cross section, a porous plate such as a perforated metal or an expanded metal, and are arranged so that the plate parts ( 3 a 1 ) ( 3 b 1 ) ( 3 c 1 ) of the adjacent AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) are opposed to each other. The ground electrode ( 3 d ) surrounds the periphery of the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ). The plate parts ( 3 a 1 ) ( 3 b 1 ) ( 3 c 1 ) are screwed through insulating members ( 42 ). The distances (Ha) to (Hc) between the plate parts ( 3 a 1 ) ( 3 b 1 ) ( 3 c 1 ) and the distances (Hd) to (Hf) between the ground electrode ( 3 d ) and the plate parts ( 3 a 1 ) ( 3 b 1 ) ( 3 c 1 ) are equal to each other. Instead of the ground electrode ( 3 d ) surrounding the periphery of the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) as shown by broken lines in FIG. 10 , a cylindrical body (or a solid porous body) of a ground electrode ( 3 d ) may be arranged in the center of the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ). In FIG. 1 , impurities (g) are deposited and accumulated on the surface of the cylindrical ground electrode ( 3 d ). Impurities are deposited not only on the cylindrical ground electrode but also on all the ground electrodes ( 3 d ).
Since the present invention uses the constant current supply ( 1 ), even if the distances (Ha) to (Hc) between the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) and the distances (Hd) to (Hf) between the ground electrode ( 3 d ) and the AC application electrodes ( 3 a ) ( 3 b ) ( 3 c ) are not equal to each other, a set constant current flows between the electrodes. Thus, it is easy to set a constant current even when three electrodes are used. In other words, three or more electrodes may be used. Alternatively, a plurality of sets of electrodes, each set comprising three or more electrodes, may be combined and arranged in a single ground electrode ( 3 d ). Thus, a large-scale device is realized. In FIGS. 5 and 7 to 10 , the fluid flowing direction is not limited to the illustrated one, but the fluid may be caused to flow in the reverse direction. | The present invention provides an epoch-making fluid reforming device which requires a small installation site, avoids clogging of pipes, allows uniform on-site adjustment, does not use chemicals or minimizes chemicals ii any, enables germ treatment, and purifies and reforms every fluid including water. The fluid reforming device has (a) a container for fluid reforming having an inlet for introducing an unpurified fluid and an outlet for discharging a purified fluid; (b) a pair or a plurality of pairs of AC application electrodes stored in the container; (c) a cylindrical ground electrode surrounding the AC application electrodes; (d) a polarity switching circuit connected to the AC application electrodes for switching the polarities of the pair of electrodes; and (e) a constant current supply having a current detector for detecting current flowing between the AC application electrodes in fluid reforming, the constant current supply keeping a current value detected by the current detector constant. | 2 |
This is a Continuation of Application No. 12/735,272 filed Sept. 28, 2010, which in turn is a National Phase of PCT/CH2008/000551 filed Dec. 30, 2008, which claims the benefit of Swiss Patent Application No. 2029/07 filed Dec. 31, 2007. The disclosure of the prior applications is hereby incorporated by reference herein in its entirety.
TECHNICAL FIELD
The invention is based on a variable hull length for watercraft according to the generic name of the first claim.
BACKGROUND OF THE INVENTION
Watercraft hulls should be able to go through the water with as little resistance as possible. For this reason, to reduce the harmful frictional resistance, various auxiliary means have been introduced, as for eg means which influence the laminar flow, as described in U.S. Pat. No. 5,819,677 or by reducing the partial wetted lifting areas on the hull or and by introducing air by having special air ducts as described in U.S. Pat. No. 5,685,253.
The not particularly good riding performance at low speed and during acceleration of gliding hulls can be improved by additional buoyancy and stability, such as fixing or integrating extensions onto the hull rear end as described in U.S. Pat. No. 3,783,810. These aids enable the vessel to get quicker to planing and at the same time reducing trim, which improves the view over the bow. The same result can also be achieved successfully by mounting rigid trimtabs.
SUMMARY OF THE INVENTION
The invention involves that the hull performance of a watercraft, whether at slow, medium or high speed operation, can be improved by means of stepped and separated added floaters, which are fixed at the stern and make specific use of static as well as of dynamic lifting mean, as well as of the omission of additional lift, according to the planing conditions.
The improvement of the hull performance at slow and medium speed is attributed to comfort, which means to generate best possible lifting in the stern area, in order to ensure a fuel saving trim position of the watercraft, as well as a good forward view especially when changing from displacement to planing speed and in addition to let the craft softly through the waves. The improvement of the hull performance at high speeds means that, when driving at a higher speed, and to achieve fuel saving in comparison to the total watercraft length this can be achieved by reducing or by the full loss of contact of the wetted surface at the stern.
The saying <the longer the better> is correct to a certain planing speed—called herein riding speed—but afterwards, friction, which means hull resistance, is hindering more than the better trim position or the reduced surface pressure of a maximised surface which means a longer hull. From this point, a smaller hull surface, which means a shorter hull is advantageous because the smaller wetted surface of a smaller, respectively shorter hull generates, due to the increased flow, nevertheless an excellent buoyancy and lets the watercraft plan more efficiently.
To enable an improvement of the hull performance for both of the different driving conditions, as well as for medium mixed driving conditions, added floaters are fixed or integrated behind the main engine, respectively at the stern of the watercraft hull with the bottom surface of the added floaters mounted higher than the watercraft's bottom so that a step is created. Unlike a conventional stepped hull which discontinues laminar flow and forces air under the hull, the additional added floaters have the primary function to reduce the surface pressure on the hull per mm 2 , as well as due to the improved three dimensional flow, to influence positively the waves behind the watercraft (fewer waves equals more efficient drive). Furthermore, with the length of added floaters a better trimming of the craft can be generated, and at higher speed from the point on which the additional wetted hull surface of the added floaters may have a negative effect, by means of steps which allow the contact to the water flow to be cut off, therefore the watercraft becomes shorter at the waterline.
The added floaters are divided, not only to make space for the stern drives, surface piercing drives, jets or outboards, but to allow the additional, deliberately limited, bottom surface to have the best possible effect in the longitudinal direction of the watercraft so that a best possible trim effect is generated and also to minimize the purpoising on the lateral axis of the watercraft when planing, as well as to achieve a better track keeping and to create an additional lift on the inner far rear surface of the craft in sharp turns, in order to prevent the watercraft hull from ditching in this running position.
As the point on which the additional bottom surface of the added floater may cause a negative effect (on the grounds of for eg the load weight and load position within the craft) may vary, an adjustable stepping of the added floater is of advantage on the craft hull. This can be controlled by the driver or automatically by an algorithm.
In addition the deadrise angle of a V hull has a large influence on the driving comfort, fuel consumption and the top speed of a watercraft. Therefore provision has been made for a variable angle adjustment on the bottom of the additional floater so that the deadrise of the craft can be adjusted to the driving condition. The installation of such an adjustable bottom into an additional fixed or integrated added floater is simpler, compared to the installation directly into the watercraft hull, as the unused part of the additional floater can be watertight and hollow or foamed and is a safe static lifting mean. In addition trim tabs can be inserted too, further improving trimming as well as the rolling of the watercraft, whereby this can also be achieved by adjusting the entire bottom plate.
The faster a planing craft runs, the more the hydrodynamic pressure point moves to the rear. A very fast planing craft would only lie on the lifting bodies and be a very high structural load for the components. The correspondingly formed or and controlled lifting bodies prevent the hydrodynamic pressure point from moving further back but stays constant on one point because of the intentionally reduced lifting effect of the lifting bodies at higher speed. All driving conditions refer to measurable and described conditions like lying at anchor or luring or planing speed or doing turns. The erratic conditions in heavy seas are not considered.
Furthermore the added floaters can be connected to each other above the waterline and may form a reasonably priced swim plate or be used as an enlargement of the watercraft's deck.
As far as the invention is concerned this is dealt with by the features of the first claim.
Core of the invention is that by means of additional floaters, which are placed aft of a watercraft stem and have a step next to the watercraft hull and can be used as buoyancy elements to the point as long as the friction of such additional bottom surface becomes negative.
When the craft is travelling at increasing speed then the added floaters lose on purpose the active contact to the damaging resistance flow, by lifting the hull further out of the water, then the step generates a clear distance from the water's surface. Preventing the added floaters from getting into contact with damaging resistance flow while running at high speed can also be achieved by a mechanical lifting mean activated manually or by a control mean. At anchor or at low speed the added floaters generate static buoyancy.
Further advantageous advantages of the invention are listed in the subclaims
BRIEF DESCRIPTION OF THE DRAWINGS
Various exemplary aspects of the invention will be described with reference to the drawings, wherein
It shows
FIG. 1 A three dimensional stem view of a watercraft with two added floaters placed laterally at the stern
FIG. 2 A schematic sideview of a watercraft hull in three different driving conditions, a) in displacement- or semi-displacement mode b) in planing mode c) in speed mode
FIG. 3 A schematic stern view of a watercraft hull with two lateral placed added floaters which compared to the stern contour are placed somewhat elevated and slightly inwards to the stern and have auxiliary lifting mean
FIG. 4 A schematic sideview of a watercraft hull with a slightly elevated rear added floater with added step with an angled upward edge
FIG. 5 A schematic sideview of a watercraft hull with a rear added floater liftable lengthwise to the vessel and has mean for pitch control
FIG. 6 A schematic sideview of a watercraft hull with a rear added floater which is height variable and has mean for stroke control
FIG. 7 A schematic sideview of a watercraft hull with a rear added floater and therein has an integrated connecting element to the watercraft stern
FIG. 8 A schematic stern view of a watercraft hull with two laterally placed added floaters on which the deadrise can be varied
FIG. 9 A schematic stern view of a watercraft hull with two laterally placed added floaters on which the deadrise can be altered and has an extendable flow mean attached onto it
FIG. 10 A three dimensional stern view of a watercraft hull with two laterally placed added floaters placed on the stern and attached therein accessories, whereas the added floaters are connected to each other by means of a plate and in between an inner floating device with propulsion drives is located
FIG. 11 a,b A schematic floor view of a watercraft hull with lateral added floaters shown here one-sided which have their mounting origin in front of or behind the stern
FIG. 12 A schematic sideview of a watercraft hull with a rear added floater which is fixed to an overhead platform element.
Only essential elements of the invention are schematically shown to facilitate immediate understanding.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1 Shows a three dimensional stern view of a watercraft hull 1 with two lateral added floaters 2 on the stern 1 a , which on the stern 1 a , according to the chain dotted line U, form a U and having outer side means 3 which run lengthwise or tapered to the watercraft longitudinal axis, as well as the inner side means 4 which are vertical or have an angle. The auxiliary bottom 5 is placed higher than the hull bottom 6 whereas the watercraft hull 1 at the stern end has a deflector 7 . Finally the added floaters 2 have a transom cover 8 and a cover 9 . A closed box form is advantageous, should the added floaters 2 be foamed, thereby creating a static lift. Instead of integrating a hull elongation with a step in the hull 1 thereby generating an additional lift in the region of the watercraft stern, the required additional space is divided into two auxiliary bottoms 5 , which are in the added floaters 2 whereby the additional surface has an effect on a longer longitudinally length measuring unit, should both of the added floaters 2 have a distance from each other. The larger the distance of both of the added floaters 2 from each other, the longer is the auxiliary bottom 5 based on the same surface. Empirical tests have shown that a length of the auxiliary bottoms 5 in general with approximately 10% of the hull 1 and a width of 2 times 20% of the width of the hull 1 have a good value, whereby the explicit goal for riding in comfort, agility etc. has an influence on the proportion size.
The more powerful the engines are and the more they are fixed in the stern region, the greater is the wish for more dynamic lifting surface and static lifting volume in the stern region so as to avoid the hull 1 from submerging and the shorter the watercraft the more it makes sense to have the added floater 2 as long as possible so that the watercraft can do it with the least necessary trim. The additional surfaces 5 offer more buoyancy but the additional wetted area means more friction. At a certain point the friction resistance is so important that the previously achieved better trimming and the low surface pressure per mm 2 is no more worthwhile, as the flow speed lets the watercraft plan in total but every additional surface does not add to any additional lift but only damaging resistance. The goal is, at this point of flow speed, that flow S on the deflector 7 stalls and the added floaters 2 are no longer active. By means of this system the hull 1 , according to such riding mode, can be lengthened or shortened at the waterline and create more lift or less friction. The function of the outer side means 3 is to lead the created flow S from the hull 1 with the least possible friction to the back, and also by intense inclination of the watercraft in turns, the added floater 2 lying on the innerside in such a turn achieves buoyancy by means of its outer side mean 3 . When riding straightforward, the inner side mean 4 together with the deadrise angle of auxiliary bottom 5 helps to further improve the straightforward stability.
FIG. 2 Shows a schematic sideview—for better comprehension the deadrise has been omitted for technical drawing reasons—of a hull 1 in three different riding conditions, a) in the displacement or semi displacement condition the hull 1 which is designed as a gliding hull and having the added floaters 2 still completely submerged, as well as the hull bottom 6 and auxiliary bottom 5 lying under the waterline WL. The flow S is little and the added floaters 2 just give more static lift As than dynamic lift Ad. When in gliding mode b) the hull 1 rides almost on the waterline WL, the hull bottom 6 , as well as the auxiliary bottom 5 lie practically on the waterline WL, the added floaters 2 only create dynamic lift Ad and in c) in the speed mode a flow stall takes place on the deflector 7 and thus the flow S flows horizontally further aft and eases behind the added floaters 2 . So such added floaters 2 do not achieve additional active lift and as the auxiliary bottom 5 is no longer actively wetted, there is little or no more friction loss in that area.
In this way the hull 1 can be automatically lengthened or shortened specifically to the waterline WL and focused on the riding conditions creating more static lift As or dynamic lift Ad or no lift at all. Therewith the frictional resistance on the added floaters 2 can be influenced. Not shown, but understandable is that in heavy seas, should the bow be pointing upwards when going through a wave, by means of the added floater 2 a counter lift force can be created with the auxiliary bottom 5 , thereby stabilizing the entire watercraft on the lateral axis as well as on the longitudinal axis.
FIG. 3 Shows a schematic stern view of a hull 1 with two lateral added floaters 2 placed somewhat higher against the stern contour, which means are stepped and run aft parallel to the hull 1 . The outer side parts for example are shifted slightly inwards, so that the flow 5 , which originates on hull 1 , can flow past to the outer side means 3 with as little resistance as possible and these can even be slightly turned up in an appropriate angle so that these can still create a positive lift even in sharp turns. The added floaters 2 are firmly fixed as modular elements on the stern 1 a or directly laminated into the hull 1 .
Auxiliary strakes 10 on the inner side parts, only shown in the drawing on the right side, yield added lifting and are useful in sharp turns.
In addition, the stall of flow S at the deflector 7 can be influenced by a variable trailing edge 11 , only shown here on the left side. This may be varied by cylinder 16 , for eg cylinders which are electrically powered or by fluids and can be operated by a computerised algorithm or manually.
From a technical design standpoint the outer side means 3 can also be flush mounted on the hull 1 which is shown in the right drawing half.
FIG. 4 Shows a schematic sideview of a hull 1 with a rear, somewhat elevated stepped added floater 2 and an integrated second additional step consisting of a secondary auxiliary bottom 12 which can show a phasing out and upward rise bevel. For better comprehension the deadrise has been omitted for technical drawing reasons. Especially in the case of leisure craft a fair valuation of the center of gravity of the craft is difficult to determine. It may be that all the passengers on board of a watercraft are at the rear of the craft and at the same time a tender is attached to the stern. Therefore it can be advantageous if the added floaters 2 are correspondingly larger dimensioned for such conditions in order to generate more static as well as dynamic lift especially when starting to plan and when in transition to the gliding phase and thus supporting the hull 1 re trimming. When riding the flow S creates enough dynamic lift Ad so that the second step with the secondary auxiliary bottom 12 does not create further active lift, therefore the friction reduction becomes of greater importance. To allow a time shifted lift effect, the auxiliary bottom 5 as well as the secondary auxiliary bottom 12 , may be equipped with a phase out angle Z instead of a horizontal standard angle X. Conceivable are also multiple steps.
FIG. 5 Shows a schematic sideview of a hull 1 with a rear added floater 2 which is trimmable lengthwise to the craft over the trim angle N. For better comprehension and technical drawing reasons the deadrise has been omitted. This configuration is preferable to standard trim tabs 13 , which also influence the flow S and also give a time limited lift. By means of auxiliary bottom 5 much better trimming may be achieved, whereby the trim angle is much smaller so that a shorter cylinder 16 can be installed in-the added floater 2 . The trim is achieved by pivot elements 14 which are connected to the hull 1 by a mounting bracket 15 and cylinder 16 which can be a fluid cylinder or an electric drive. The trim of the added floater 2 may be achieved manually or over an algorithm in controller 17 with corresponding trim sensors 18 . Of course instead of trimming the entire added floater 2 , the auxiliary bottom 5 can only be trimmed.
FIG. 6 Shows a schematic sideview of a hull 1 with a rear added floater 2 which is height adjustable. For better comprehension the deadrise has been omitted for technical drawing reasons. The problem to calculate the exact point at which the added floater 2 does not have any added dynamic lift Ad and where the friction causes overproportional damage, especially with craft with varying numbers of people aboard, ballast and weight distribution, the most elegant solution is to be able to vary the height of the added floater 2 independent of the hull 1 respectively to the hull bottom 6 , so that the step, which means the height difference between hull bottom 6 and auxiliary bottom 5 can be controlled and corrected correspondingly. It is of advantage if the added floater 2 or the auxiliary bottom 5 is brought up as a whole, respectively the requested area is lifted up preferably parallel. Then a one-sided, which means ramp similar lifting, may lead to a “sticky” effect of the flow at the bottom of the added floater 2 or auxiliary bottom 5 and therefore does not create the requested, clear stall at the deflector 7 , which shortens the wetted hull surface rather nicely and hereby reduces the friction at this point to zero. The lifting is achieved by lifting mean 19 , eg by a screw driven mean or a parallelogram 19 a , which is hinged on one side onto the pivot elements 14 and on the other side at the added floater 2 on hull 1 . The stroke H is achieved by the cylinder 16 which is attached to the parallelogram 19 and is fixed to the hull 1 . The cylinder 16 can be controlled manually or by a controller 17 which sets the stroke position on stroke H by speed gauge 20 or rpm gauge and other sensors.
FIG. 7 Shows a schematic sideview of a hull 1 with a rear added floater 2 . For better comprehension the deadrise has been omitted for technical drawing reasons. Instead of fixing the added floater 2 higher, which means stepped onto the hull 1 a of the watercraft, shows first a firm link element 5 a on hull 1 , whereby the co-bottom 5 b is put on the same level as hull bottom 6 so as to connect both parts more securely to each other, so that, as for eg by race events, these can withstand the high forces while wave jumping. But also shipyards, that modify their watercraft with regard to the installation or fixation of the added floaters 2 , can also take the opportunity of extending their hull 1 so as to have an even larger model. This can be accomplished at a reasonable price by installing the added floater 2 , and the link element 5 a also enables a permanent connection to the other added floater 2 on the opposite side.
FIG. 8 Shows a schematic sideview of a hull 1 with two lateral added floaters 2 , on which the deadrise can be varied by means of variable auxiliary bottom 5 which is advantageously fixed to the pivot point DP and the deadrise angle KW can be modified by cylinder 16 . This function has two aims: on the one hand the degree of comfort can be set so that the watercraft moves softer through the waves thanks to a deep V of the added floaters 2 , and the craft uses less fuel. On the other hand the movable auxiliary bottom 5 conveniently replaces the described target in FIG. 6 of friction reduction from a certain point by withdrawing the area of auxiliary bottom 5 from the flow S. Instead of lifting the entire added floater 2 , in this technical solution only the deadrise angle KW is changed so that the flow S does not have any further active contact with the auxiliary bottom 5 . The controlling of cylinder 16 is achieved exactly as in FIG. 6
FIG. 9 Shows a schematic stern view of a hull 1 with two lateral added floaters 2 on which the deadrise can be varied over the deadrise angle KW to KW 1 , by means of an auxiliary bottom 5 fixed to the pivot point DP on which a flow mean 23 is attached, whereby the flow mean 23 can be led over the line of the hull bottom 6 out into the deadrise angle region KW 1 .
The flow mean 23 is a straight or bent plate and functions as a trim or steering mean. in front of the extended flow mean 23 , in the KW 1 area, a flow brake develops, therefore a lifting Ad on the hull 1 is generated, thereby changing the watercraft's trim position. Trimming means also steering, thus when lowering the flow mean 23 on one side, an additional resistance is generated which moves the watercraft in a turn around the vertical axis, thereby pushing the craft to a new course or keeping it simply but safely on track. The settings of the deadrise KW and KW 1 is generated by means identical to those described in FIGS. 6 and 7 . Of course, every deadrise angle adjustment KW and KW 1 can also be achieved by adjusting the added floaters 2 .
FIG. 10 Shows a three dimensional stern view of hull 1 with two lateral added floaters 2 placed parallel on the stern and the accessories 13 , 24 , 25 fitted therein, for eg. standard trim tabs 13 , exhaust gas discharge 24 , underwater light 25 , rudder 29 and not shown here sidethrusters and or small “go home” drives and many more and are summarized as technical mean 30 , whereby the added floaters 2 are connected to each other by plate 26 , which may be used as a bathing platform or as part of an extended deck. Furthermore the division of the required additional lifting mean on the stern into two separate external added floaters 2 can serve so that the free space between the additional floaters 2 can be used as an inner floating device 27 which can create limited additional buoyancy and for eg can be equipped with propulsion drives 28 , as for eg with propeller, jet or paddlewheel so that the engines can be pushed even further back into the stern area allowing more room for the persons on board, but at the same time allowing easy compensation regarding static lift As and dynamic lift Ad by means of added floaters 2 .
Because of the attachment of the added floaters 2 to the hull 1 it is also possible to design the added floaters 2 of a material especially suitable for this stern part which can be different from the hull 1 and can locally generate more stiffness and or less weight.
FIG. 11 a ) shows a schematic bottom view of a hull 1 with a lateral added floater 2 shown from one side which is preferably fixed to the stern 1 a of the hull 1 for technical production and attachment reasons and thereby has a relevantly greater percentage influence over the entire wetted area of the hull bottom 6 when varying the auxiliary bottom's 5 lifting.
b ) shows a schematic bottom view of a hull 1 with a lateral added floater 2 shown from one side which for production relevant reasons, as for eg the existing molds at the shipyards, which already have lateral extensions built into their hull bottoms, onto which existing extensions the added floaters 2 can be directly attached, whereby the effect of the auxiliary bottom 5 is lower if the watercraft keeps the same in the entire length as in FIG. 11 a . Both of the installations have in common that the force source whether in front of or behind the stern 1 a has an influence on the wetted surface of the entire watercraft as well as on the static lift.
FIG. 12 Shows a schematic sideview of a hull 1 with a rear added floater 2 which is fixed onto an overhead platform element 31 . Should there be an existing mold or for weight optimization reasons, it may be of advantage to leave the hull 1 as it is, and not to have any material changes but instead to install an adequate stern platform which is anyway a requested after market product, which at the same time houses the added floater 2 , and so that the stern form is not affected or and to implement at the same time a light and firm material for such an additional floater 2 . The gap between hull 1 and added floater 2 can be masked elegantly or shown as a design element. The platform element 31 can be fixed rigidly to the stem 1 a or used as a lifting platform so that additional benefits arise from the added floaters 2 .
Of course the invention is not only applicable on shown and described examples.
Drawing List
1 hull
1 a stern
2 added floater
3 outer side mean
4 inner side mean
5 auxiliary bottom
5 a link element
5 b co-bottom
6 hull bottom
7 deflector
8 transom cover
9 cover
10 auxiliary strake
11 variable trailing edge
12 secondary auxiliary bottom
13 standard trimtabs
14 pivot element
15 mounting bracket
16 cylinder
17 controller
18 trim sensor
19 lifting mean
19 a parallelogram
20 speed gauge
21 rpm gauge
23 flow mean
24 exhaust gas discharge
25 underwater light
26 plate
27 inner floating device
28 propulsion drive
29 rudder
30 technical mean 13 , 24 , 25 , 29
31 platform element
WL waterline
S flow
Ad dynamic lift
As static lift
H stroke
X standard angle
Z phase out angle
N trim angle
DP pivot point
KW deadrise angle | Watercraft having a hull and a stern and including at least two additional floaters stretching out at the stern of a watercraft, wherein the additional floaters form a U at the stern of the watercraft, wherein the additional floaters and the hull each include bottoms and the bottoms of the additional floaters are positioned above the hull bottom, and wherein the bottoms of the additional floaters are stepped by one or more steps. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a process for treating a cyanic liquid containing copper(I) cyanide complex ion.
When industrial effluents containing copper(I) cyanide complex ion are discharged, CN groups of copper(I) cyanide complex ion should be thoroughly decomposed prior to the discharge for prevention of environmental pollution. Hitherto, the CN group of copper(I) cyanide complex ion has been generally decomposed by a so-called alkali-chlorine process. This conventional process comprises adding sodium hypochlorite in an amount corresponding to the concentration of the copper(I) cyanide complex ion to the liquid to be treated while maintaining the pH of the liquid at a certain range during the treatment and decomposing the CN groups into carbon dioxide and nitrogen. This process is usually adopted in the treatment of a cyanic liquid containing a CN concentration of 2,000 ppm or less, especially under 1,000 ppm. When the cyanic liquid has a high CN concentration such as 10,000 ppm or higher, the treatment time is much longer and the amount of sodium hypochlorite is enormous so that it is practically impossible to thoroughly decompose the CN groups of copper(I) cyanide complex in a single batch. For treatment of the cyanic liquid having a high CN concentration such as 10,000 ppm or higher by the above conventional process attaining a decomposition rate of 90% or more requires diluting the cyanic liquid to 2,000 ppm or less and then subjecting the diluted liquid to treatment in several batches. These operations naturally make the working less efficient.
In order to overcome the difficulties of the conventional process, there has been proposed an improved process which comprises adding an aqueous solution of at least one ferrous salt selected from the group consisting of ferrous sulfate, ferrous chloride, ferrous nitrate, ferrous acetate, ammonium ferrous sulfate and ferrous iodide to a cyanic liquid containing a copper(I) cyanide complex ion and heating the liquid to 130° C. or higher (cf. Japanese Patent Publication No. 20036/1982). By the improved process, the cyanic liquid having a CN concentration of from several ppm to 100,000 ppm can be effectively treated in a single batch without dilution of the liquid. Since, however, the above improved process requires a ferrous salt for decomposition of the CN groups of copper(I) cyanide complex ion, a sludge containing copper and iron is formed in the treated liquid, and the increased amount of the sludge tends to accumulate in a discharge pipe and makes the separation of the sludge from the liquid troublesome. It is particularly disadvantageous that the recovery of copper becomes difficult, because the sludge contains iron in addition to copper.
SUMMARY OF THE INVENTION
A main object of this invention is to provide a process for treating a cyanic liquid containing copper(I) cyanide complex ion efficiently by decomposing CN groups of copper(I) cyanide complex ion in a high decomposition rate. Another object of the invention is to provide a process for treating a cyanic liquid containing copper(I) cyanide complex ion which produces only a small amount of sludge. These and other objects are fulfilled by heating the cyanic liquid at a temperature of not lower 200° C. in the presence of a water-soluble metal hydroxide.
DETAILED DESCRIPTION OF THE INVENTION
The cyanic liquid containing copper(I) cyanide complex ion to be treated by the process of the invention includes waste copper cyanide plating solutions comprising predominantly copper(I) cyanide complex ion, waste cyanide solutions for extraction of gold, silver, nickel, etc. from a copper article plated with said metals comprising alkali cyanides (e.g. sodium cyanide, potassium cyanide), etc. Namely, according to the invention, any waste liquid containing copper(I) cyanide complex ion such as dicyanocopper ion (Cu(CN) 2 - ), tricyanocopper ion (Cu(CN) 3 -- ) and tetracyanocopper ion (Cu(CN) 4 --- ) is treatable.
The CN concentration of the copper(I) cyanide complex ion in the liquid to be treated may be usually from several to 100,000 ppm, preferably from 100 to 80,000 ppm. The liquid having such a high CN concentration can be treated as such, i.e. without dilution, according to the process of the invention.
Specific examples of the water-soluble metal hydroxide are alkali metal hydroxides (e.g. lithium hydroxide, sodium hydroxide, potassium hydroxide), alkaline earth metal hydroxides (e.g. barium hydroxide, calcium hydroxide, strontium hydroxide), etc. Among them, sodium hydroxide and potassium hydroxide are preferred. The presence of these metal hydroxides in the cyanic liquid is effective in efficient decomposition of the CN groups of copper(I) cyanide complex ion. The amount of the metal hydroxide may be at least 0.2 mole, preferably at least 1 mole to 1 mole of the copper(I) cyanide complex ion. The metal hydroxide, which is in the form of solid or of aqueous solution, may be added to the liquid all at once before the treatment or portionwise during the treatment.
The cyanic liquid is heated at a temperature of not lower than 200° C. When the temperature is lower than 200° C., the CN groups of copper(I) cyanide complex ion are not thoroughly decomposed. Preferably, the treatment temperature is higher than 220° C. in order to assure the complete decomposition of the CN groups. Usually the process of the invention is carried out in a high pressure reactor made of plain carbon steel, stainless steel, etc. and the treatment temperature is preferably not higher than 300° C. in view of the strength of the reactor. The liquid may be heated by a heater immersed therein or by heating the reactor from the outside. Also, the liquid may be heated by injecting high-pressure steam therein. The use of such steam singly or in combination with some other heating means is advantageous in effecting uniform treatment since the liquid can then be agitated by the blow of steam.
During the treatment, ammonia is generated and preferably occasionally removed from the reactor through an exhaust vent attached to the reactor in order to accelerate the decomposition of the copper(I) cyanide complex ion.
As stated above, the process of the invention uses no heavy metals but the water-soluble metal hydroxide. Therefore, the amount of sludges formed in the treated liquid is not as great as in the prior processes.
The present invention will be explained further in detail by the following Examples.
EXAMPLES 1 TO 6 AND COMPARATIVE EXAMPLES 1 AND 2
To a 6 liter autoclave made of stainless steel, an aqueous cyanic liquid (4 liters) containing total CN concentration of 5,500 ppm (measured according to the procedure as described in JIS (Japanese Industrial Standard) K 0102 (1971), 29.1.2 and 29.2), 4,000 ppm of which was assigned to the CN groups of tricyanocopper(I) complex ion (determined by dissolving a sample of the liquid into a mixture of nitric acid and sulfuric acid, evaporating the resulting solution to dryness, dissolving the residue into water, measuring quantitatively the copper content by atomic absorption spectrochemical analysis, calculating the amount of tricyanocopper ion (Cu(CN) 3 -- ) from the measured amount and calculating the CN concentration on the basis of the amount of (Cu(CN) 3 -- )), was charged, and an aqueous solution of the water-soluble metal hydroxide as shown in Table 1 was added thereto. The resultant mixture was heated under the predetermined conditions as shown in Table 1. The results are shown in Table 1.
TABLE 1__________________________________________________________________________ Metal hydroxide CN concentration (ppm) Temp. Time after treatment CN decomposition NaOH KOH (°C.) (hr) (ppm) (%)__________________________________________________________________________Example 1 3000 -- 200 6 480 91.3Example 2 3000 -- 210 6 120 97.8Example 3 3000 -- 220 6 6.4 99.9Example 4 550 -- 230 6 360 93.5Example 5 3000 -- 230 6 0.10 99.99Example 6 -- 4200 230 6 0.06 99.99Comparative -- -- 220 6 1920 65.1Example 1Comparative 3000 -- 180 6 1800 67.3Example 2__________________________________________________________________________
As is clear from the results shown in Table 1, the decomposition rate in Examples 1 to 6 (according to the invention) is higher than 90%. Also, in the treated liquid, only the cuprous oxide sludge was formed and no other superfluous sludge was substantially formed. | This invention relates to an improved process for treating a cyanic liquid containing copper(I) cyanide complex ion which comprises heating the liquid at a temperature of not lower than 200° C. in the presence of a water-soluble metal hydroxide, whereby the decomposition of the CN group of copper(I) cyanide complex ion is accomplished in a high rate in a single batch producing a relatively small amount of sludge even when the liquid has a high CN concentration. | 8 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to a method for wafer analysis. More particularly, the present invention relates to a method utilizing artificial neural network for wafer analysis.
(2) Prior Art
There are numerous steps in wafer fabrication. In these steps, there must be some measuring and monitoring operations for qualification. The quality of wafer fabrication could be analyzed by some data such as film thickness, electricity, electric resistance, and impurity concentration etc. Then, the problems of product could be found in time to prevent the waste of cost.
In tradition, the way to monitor the quality of wafers is to test the same site continuously for several times and check if any error exists in machine. If any error does exist, the cause of the error is usually examined by human operator with experience to analyze, determine the cause and to improve the process. Although this method could solve problem and get improvement of wafer fabrication, it wastes too much time and manpower. Besides, the risk of manpower does exist. Experience deficiency of analysis and a wrong judgment would cause more waste of time and manpower, and increase the cost.
FIG. 1 shows a schematic diagram of risk analysis for wafer analysis. After all process of wafer fabrication 102 completed, all wafers 101 could be divided into two parts, good wafers 103 and bad wafers 104 , respectively. Then, after the step of wafer test 105 , the part of good wafers 103 could get the result of pass 106 and the part of bad wafers 104 could get the result of fail 107 . However, sometimes wrong judgment could happen. Such as the part of good wafers 103 would get the result of fail 107 and result in risk of product 108 ; or the part of bad wafers 104 could get the result of pass 106 and result in risk of consumer 109 . Both risk of product 108 and risk of consumer 109 resulting from the wrong judgment would cause great loss.
Therefore, it is necessary to provide a method for wafer analysis which could save time and reduce risk of wrong judgment.
SUMMARY OF THE INVENTION
An object of the present invention is to solve problems of the wastes of time and manpower in wafer analysis. Besides, there are still some risks by using artificial analysis. If experience and ability of judgment of analyzers are not enough to make correct analyses, incorrect analyses might cause more waste of time and manpower.
To achieve the object mentioned above, the present invention utilizes the theory and concept of artificial neural network, and combines JAVA software to create a system which could monitor the testing result and analyze abnormal conditions. The steps of the method of the system of the present invention include: first of all, providing a test unit for wafer test and generating a plurality of test data; next, transmitting the test data to a processing unit for transferring to output data; then, comparing the output data with predictive value and modifying bias and making the output data close to the predictive value, and repeating the steps mentioned above to train this system; finally, analyzing wafers by the trained system. The invention constantly provides all abnormal results of current wafer test to train the system with cumulative experiences. The system could analyze any future abnormal condition and find root cause in time with the cumulative experiences.
The efficacy of the present invention is to replace the system with human resource. Using this system to analyze wafers not only saves time, but also reduces manpower and the risk resulting from artificial analysis.
In the following description of the preferred embodiment, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration a specific embodiment in which the invention may be practiced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing risk of wafer analysis.
FIG. 2 is a schematic diagram of one embodiment of the system of the present invention.
FIG. 3 is a schematic diagram of one embodiment of a model of artificial neural network.
FIG. 4 is a flow chart of one embodiment of the system of the present invention.
FIG. 5 is a schematic diagram of one embodiment of test result of the present invention.
FIG. 6 is a flow chart of one embodiment of transferring process of the system of the present invention.
FIG. 7 is a schematic diagram of one embodiment of model of time delay artificial neural network.
FIG. 8 is a schematic diagram of one embodiment of model of recurrent artificial neural network.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 shows one embodiment of a wafer analysis system of the present invention, which includes a processing unit 202 and a learning and comparing unit of artificial neural network (ANN) 203 . Test data from a test unit 201 are received by the processing unit 202 . The learning and comparing unit of ANN 203 is connected with the processing unit 202 . The test data are computed in the learning and comparing unit of ANN 203 by instructions from the processing unit 202 . The computed test data are compared with a predictive value in a database 204 by the learning and comparing unit of ANN 203 for training the system to make results of systematic analysis approach to results of artificial analysis. Finally, the results are outputted by an output unit 205 .
In an embodiment, the test unit 201 could be a plurality of testers, which could test wafer and provide test data to the processing unit 202 . The processing unit 202 could be a computer in this embodiment, and the computer includes at least a processor and a memory. Moreover, the computer is installed with software of the learning and comparing unit of ANN 203 and database unit 204 . Therefore, the test data could be transferred by the system to an output data, and the output data could be outputted by the output unit 205 . The learning and comparing unit of ANN 203 comprises a computer-readable medium having programmable instructions of artificial neural network which would be written by JAVA programmable language. Results of wafer test could be analyzed by executing these instructions. In this embodiment, the database unit 204 comprises hard disks, CD-ROM, RAM (random access memory), or ROM (read-only memory).
FIG. 3 shows a model of artificial neural network, which describes logic operators of the wafer analysis system of the present invention. The symbol X means the input 301 of neural unit, and the symbol W means weight 302 . The symbol ΣXiWi means bias 304 , which express a summation of each input multiplied by the weight. The symbol f(.) means an activation function 305 , which has several types and usually is a non-linear function. The purpose of the activation function is used as a mapping function to obtain an output (Y) 306 by utilizing bias 304 . The output 306 is the result which we want. The input 301 is multiplied by the weight 302 and sent into an artificial neural network (ANN) unit 303 for operation. The bias 304 is adjusted to larger or smaller for training the artificial neural network. The initial value of the bias 304 is usually between +1 and −1 generated at random. The bias 304 could be considered to a kind of weighted effect. When the bias 304 is large, the connected ANN unit 303 would be stimulated more easily and the artificial neural network would be influenced more. Otherwise, there is almost no influence to the artificial neural network when the bias 304 is small. Therefore, small bias 304 usually could be deleted for saving time and space of the computer.
FIG. 4 shows a flow chart of one embodiment of the system of the present invention. At processing block S 401 , test data are provided by a test unit after wafer test. In this embodiment, a wafer having three hundred dies is provided to be tested, and six dies are tested at the same time, Therefore, all dies could be tested after fifty times. After wafer test is completed, the test data of wafer test are received by the wafer analysis system of the present invention.
At processing block S 402 , the test data are transmitted to a processing unit for transferring to output data. In this embodiment, the test data are received and transferred to be an output data by the wafer analysis system. The transferring process would be described detail in FIG. 6 later.
At processing block S 403 , the output data is compared with a predictive value and changed by modifying bias to close to the predictive value. This system could be trained by repeating the steps mentioned above. Because the output data which generated by an un-trained artificial neural network might be not equal to the predictive value, the step of comparing the output data with the predictive value is necessary. By repeating the steps S 401 to S 403 , the artificial neural network system could be trained to identify output data of any kinds of result of wafer test, which include normal result and abnormal results such as line fail, local fail (edge), local fail (ring), low yield, site unbalance, etc. The magnitude and range of these kinds of output data having different values could be set by user before training the system. All abnormal conditions in wafer test could be provided continuously during of training of the system. Through enough training times and experiences of the system, the purpose which the output data could be close to the predictive value would be reached.
At processing block S 404 , wafer could be analyzed by the trained system. In analyzing wafers, the corresponding output data could be found out by the trained system having an ability which is similar to human experiences, and the output data could be stored and transferred to the tester. Moreover, the tester having problems would alarm and stop test, and the relevant engineer could deal with the problems. Therefore, wafers are identified and divided to several conditions by the trained system, which include: normal, line fail, local fail (edge), local fail (ring), low yield and site unbalance. For example, a linear abnormal wafer artificially identified will also be identified by the trained artificial network system, and a signal of “line fail” would be obtained.
FIG. 5 shows a test result of one embodiment of the present invention. In FIG. 5 , the value 1 means the test result for pass, and the value −1 means the test result for fail. The value 0 means un-tested. Each site of the wafer has a value, and the test data could be divided into fifty sets and each set has six test values.
FIG. 6 shows a flow chart of the transferring process of S 402 in FIG. 4 . At processing block S 601 , the test data provided by the test unit is received. At processing block S 602 , the test data are multiplied with weight and a plurality of weighting results would be obtained. In this embodiment, fifty sets of the test data are calculated respectively by the artificial neural network system, and six test values of each set are multiplied with a weight individually. Because the value of weight would be converged to a constant value, it doesn't need to be defined. Therefore, the test data still are fifty sets and six values of each set are multiplied with a weight. The result is called “weighted results”.
At processing block S 603 , all the weighted results are summed and a bias would be obtained. In this step, the test data are fifty sets, however, each set has just one value.
At processing block S 604 , the bias is substituted into the activation function to obtain an output data. In this step, the activation function would be different according to different model of artificial neural network. However, the purpose of the activation function is to transfer the bias in step S 603 to be an output data, which is between 0 and 1. Therefore, the result of wafer test could be judged according to the output data.
The value of the output data calculated by the artificial neural network system are not necessarily an integral. For example, the predictive value of site unbalance which is one kind of abnormal condition is 1 for abnormal condition, and the predictive value is 0 for normal condition. Then, the judgment of the artificial neural network could be “site unbalance” if the value of output data is larger than 0.5. Otherwise, the judgment could be “normal” if the value of output data is smaller than or equal to 0.5. Besides, there is another way to define site unbalance. The predictive value of site unbalance is (0, 1) for abnormal condition and (1, 0) for normal condition. Therefore, the judgment of the artificial neural network could be defined by a formula (a, b). The judgment could be “site unbalance” if the value of “a” is smaller than the value of “b”. Otherwise, the judgment could be “normal” if the value of “a” is larger than or equal to the value of “b”.
FIG. 7 shows a model of a time delay neural network which is one of two major models of artificial neural network of the invention. Input data 701 include X 1 (t)˜X 32 (t). The artificial neural network system can be defined to memorize the previous ten input data. For example, the ten input data 702 previous to the input data including X 1 (t- 10 )˜X 32 (t- 10 ) 701 are also included to be calculated. This particular feature of the time delay artificial neural network system is a memory function which is used to expand input data range being calculated by defining and memorizing the previous input data and calculating the previous and present input data at the same time. The advantage of this feature is to use the previous input data as reference data to train the current artificial neural network so that the trained artificial neural network can generate more significant result of wafer analysis.
FIG. 8 shows a model of recurrent neural network which is another model of artificial neural network of the invention. The calculated data will be transmitted into hidden layer 802 from context layer 803 to be calculated together with the data in input layer 801 when the data are calculated in hidden layer 802 . The result then will be transmitted to output layer 804 . The specific feature of the recurrent neural network system is data accumulation during calculation. All data used to train the artificial neural network system are included, but those old enough data will be gradually ignored to maintain a trained and effective artificial neural network model. The advantage of this recurrent neural network is the capability of accurately judging and analyzing data. However, the speed of calculation is slower than that of the time delay artificial neural network due to the large data quantity.
The test result obtained from wafer test such as line fail or local fail could be used to train the above-mentioned models of artificial neural network. The trained artificial neural network will use the bias obtained by training to calculate the result. This result is used to determine the condition of wafer test. The tester reacts according to the condition, and alarm and stop test automatically, when the condition is abnormal.
Artificial neural network could establish a non-linear model, and except various kinds of variable to be input data. Moreover, the more quantity of data stored in artificial neural network system, the higher accuracy result would be obtained. Therefore, applying the skills of artificial neural network in wafer analysis not only saves time and improves efficiency and accuracy, but also reduces manpower and the risk resulting from artificial analysis.
The specific arrangements and methods herein are merely illustrative of the principles of this invention. Numerous modifications in form and detail may be made by those skilled in the art without departing from the true spirit and scope of the invention. | A method for wafer analysis with artificial neural network and the system thereof are disclosed. The method of the system of the present invention has several steps, including: first of all, providing a test unit for wafer test and generating a plurality of test data; next, transmitting the test data to a processing unit for transferring to output data; then, comparing the output data with predictive value and modifying bias and making the output data close to the predictive value, and repeating the steps mentioned above to train this system; finally, analyzing wafers by the trained system. Using this system to analyze wafers not only saves time, but also reduces manpower and the risk resulting from artificial analysis. | 6 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to compositions and methods for neutralizing acidic streams in an olefin or styrene production plant. More specifically, the invention relates to neutralizing agents for dilution steam systems in the steam cracker process and their use for reducing acid corrosion, minimizing fouling and preventing product contamination.
BACKGROUND OF THE INVENTION
[0002] Dilution steam is an integral component in the process of production of ethylene, propylene and other byproducts via the pyrolysis of hydrocarbon feedstock. Dilution steam promotes the formation of desired olefins by reducing the hydrocarbon partial pressure in the pyrolysis furnace and it extends the run length of the furnace by slowing the rate of coke deposition.
[0003] After the hydrocarbon feedstock is pyrolyzed in the cracking furnace, the effluent gases must be rapidly cooled, i.e., quenched, in order to prevent the recombination of the reactive olefins into unwanted mixtures of oligomers, polymers and fused aromatic structures. During this quenching process, steam is condensed and the resultant hot water is used for heat recovery, the water condensate is cooled further to be used in the quenching process, and a portion of the condensate is processed for re-use as dilution steam.
[0004] This “steam cracking” process (pyrolysis of hydrocarbon feedstock in the presence of dilution steam) also produces a small quantity of less desirable by-products such as carbon monoxide, carbon dioxide, acetaldehyde, and acetic acid. The organic acids, acetic acid, propionic acid, formic acid, and to a lesser extent higher C 4 -C 6 organic acids promote corrosion in the aqueous environs of the quench water system, the quench water cleaning vessels (oil/water separator, coalescers, process water stripper) and the dilution steam generator. Another contributor to acidic conditions in the “dilution steam system” (a system which includes the quench water system, oil/water separator, process water stripper, dilution steam generator and dilution steam piping) are sulfur-based acids, formed from cracking of sulfur compounds that come with or are added to the hydrocarbon feedstock. These acidic byproducts are neutralized with an alkaline agent.
[0005] In many systems, the neutralizing agent of choice for dilution steam systems was caustic, NaOH, and this alkalizer is cost-effective provided that the dilution steam generator has sufficient size or design features that prevent the incidental carry-over of sodium ions with the dilution steam. Low levels of carry-over of sodium with the dilution steam can cause a greater degree of furnace coking and shorter furnace run length, while high levels of carry-over of sodium can destroy the mechanical properties of the furnace radiant tubes (e.g., sodium embrittlement).
[0006] To circumvent the hazards associated with sodium carry-over, a large number of ethylene producers have opted to control pH in the dilution steam system with the use of neutralizing amines. Although monoethanolamine (MEA) is a cost-effective amine, it reacts with acetic acid in dilution steam condensate to form MEA-acetate salt. In an aqueous solution, this salt generates a buffered pH condition wherein a small addition of acid does not greatly decrease the pH and a small addition of base does not greatly increase the pH. Even though this buffering condition protects against pH shifts into the more corrosive acidic regime, it also requires use of large amounts of MEA to raise the pH into the protective pH range to avoid solubilization of iron oxides and thereby prevent corrosion.
[0007] Even though MEA has a relatively low volatility ratio in a steam boiler, some amine will carry over with the steam phase in the boiler. When an amine, such as MEA, goes to the pyrolysis furnace, the amine is cracked to form ammonia and hydrocarbon by-products. Ammonia is a contaminant for the ethylene product because it poisons the catalysts that are used to produce polyethylene and ethylene copolymers. When ethylene product is off-specification due to ammonia, the ethylene product is sent directly to the flaring system until the product is back on specification. Since ammonia is a base, it can raise the pH in the quench water of the dilution steam system. If the addition of the ammonia is uncontrolled, then the quench water can become too alkaline and can promote stabilized emulsions in the quench oil/water separator, causing premature fouling of the dilution steam generator.
[0008] Thus, a need for a more effective neutralizer exists.
SUMMARY OF THE INVENTION
[0009] One aspect of the invention is a method for inhibiting fouling and corrosion of equipment in an ethylene production plant. The method comprises injecting a neutralizing agent into a dilution steam system, the neutralizing agent having a volatility index of less than 0.005, and a pKa of about 12 to about 20. The neutralizing agent further being substantially sodium-free and when the neutralizing agent is a choline salt, the choline salt is stabilized by about 2 wt. % to about 10 wt. % alkanolamine.
[0010] Another aspect of the invention is a method for inhibiting fouling and corrosion of equipment in a styrene production plant. The method comprises injecting a neutralizing agent into a dilution steam system, the neutralizing agent having a volatility index of less than 0.005 and a pKa of about 12 to about 20, and being substantially sodium-free.
[0011] Yet another aspect is a method for inhibiting fouling and corrosion of equipment in an ethylene or styrene production plant. The method comprises injecting a neutralizing agent into a dilution steam system. The neutralizing agent comprises a choline salt stabilized by about 2 wt. % to about 10 wt. % alkanolamine.
[0012] A further aspect of the invention is a stabilized choline composition that comprises a choline salt, a solvent, and from about 2 wt. % to about 10 wt. % of an alkanolamine based on the total weight of the composition.
[0013] Other objects and features will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic of an olefin dilution steam system.
[0015] FIG. 2 is a schematic of a styrene dilution steam system.
[0016] FIG. 3 is a graph of pH versus concentration of neutralizing agent for 100% w/w monoethanolamine (MEA), 66.4% w/w MEA, 39.6% w/w choline hydroxide and 12% w/w MEA, 41% w/w choline hydroxide and 9% w/w MEA, 42.3% w/w choline hydroxide and 6% w/w MEA, and 43.4% w/w choline hydroxide and 3% w/w MEA.
[0017] Corresponding reference characters indicate corresponding parts throughout the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Neutralizing agents for ethylene and styrene production plants have been discovered to effectively prevent or reduce fouling of the equipment with undesirable hydrocarbon deposits and to inhibit product contamination. Such neutralizing agents have a relatively high pKa and a relatively low volatility index (V/L) and are substantially sodium-free.
[0019] The high pKa allows the neutralizing agent to be effective at increasing the pH of the aqueous solution in the dilution steam system while minimizing the amount of neutralizing agent needed. In selecting a neutralizing agent with a high pKa, once the acids are stoichiometrically neutralized, only a small excess of the high pKa neutralizer is needed to increase the pH of the boiler water. The high pKa of the neutralizing agent helps to reduce the level of treatment needed in the waste water system since it allows for a smaller amount of the neutralizing agent to be used.
[0020] Due to the low volatility of the neutralizing agent, it is less likely that the neutralizing agent will go with the steam phase in the boiler. Since the neutralizing agent is less likely to be in the steam phase, the neutralizing agent is also less likely to reach the pyrolysis furnace. When an amine used as a neutralizing agent enters the pyrolysis furnace, it is cracked to form ammonia and hydrocarbons. The ammonia is a contaminant in the ethylene product because it poisons the polymerization catalysts. Ammonia can also increase the pH of the quench water, but when the ammonia addition is uncontrolled, the quench water can reach a pH that is too high and emulsions can form that impede the separation of the oil and water. The low volatility of the neutralizing agent avoids formation of these emulsions which can cause fouling of the dilution steam generator.
[0021] The neutralizing agent is sodium-free or substantially sodium-free so that carry over of sodium ions into the furnace does not occur or is minimal. Such carry over can cause furnace coking, shorter furnace run length, or sodium embrittlement of the furnace radiant tubes. The sodium embrittlement makes the radiant tubes become like glass and significantly reduces the useful life of the furnace radiant tubes. A neutralizing agent is “substantially sodium-free” if the neutralizing agent or a composition comprising the neutralizing agent contains an amount of sodium that does not result in furnace coking or result in sodium embrittlement in any component of the dilution steam system. Preferably, the neutralizing agent is sodium-free.
[0022] A method of the invention inhibits fouling and corrosion of equipment in an ethylene production plant and comprises injecting a neutralizing agent into a dilution steam system, the neutralizing agent having a volatility index of less than 0.005 and a pKa of about 12 to about 20, and being substantially sodium-free.
[0023] A method for inhibiting fouling and corrosion of equipment in an ethylene production plant, the method comprising injecting a neutralizing agent into a dilution steam system, the neutralizing agent comprising a choline salt stabilized by about 2 wt. % to about 10 wt. % alkanolamine.
[0024] The process of cracking a hydrocarbon feed produces the desired olefins, primarily C 2 -C 4 olefins such as ethylene, propylene, butylene, and butadiene. The cracking process also produces by-products such as carbon monoxide, carbon dioxide, acetaldehyde, and organic acids such as acetic acid, propionic acid, formic acid and some C 4 to C 6 organic acids. Also, some sulfur-based acids are products of the cracking of sulfur compounds contained in the hydrocarbon feed. Addition of the neutralizing agent into the dilution steam system reduces damage to the system that can be caused by the presence of some of these by-products as described in more detail above.
[0025] The dilution steam system used in the methods described herein can comprise a furnace, a quench water tower, a quench water separator, a coalescer, a process water stripper, and a dilution steam generator. A representative dilution steam system for ethylene production is shown in FIG. 1 , in which a hydrocarbon feedstock 10 is fed into a pyrolysis furnace 12 and the effluent from the pyrolysis furnace contained in an effluent line 14 is fed to a quench water tower 20 . The quench water tower 20 reduces the temperature of the gases in the overhead line 24 by spraying cool water from the top of the quench water tower 20 . This process recovers energy, reduces undesirable side reactions, and condenses a fraction of the pyrolysis gas. The quench water tower bottoms are contained in a quench water tower line 22 and are sent to the quench water separator 30 . The quench water separator 30 separates hydrocarbons from water and is the first step in cleaning the water exiting the quench water tower. Light hydrocarbons are contained in a light hydrocarbons line 34 and are separated from the water contained in the quench water separator line 32 that is sent to the coalescer unit comprising filters 36 and a coalescer 40 . The coalescer unit further improves the quality of the process water by removing organic and solid materials by using the filters 36 to recover solids and the coalescer 40 to reduce hydrocarbons. The water contained in the quench water separator line 32 from the quench water separator 30 is first sent to the filters 36 of the coalescer unit and after filtering the water contained in the filter line 38 is sent to the coalescer 40 . The coalescer 40 separates light oils from water. The light oils contained in the light oil line 44 from the coalescer are sent to the quench water separator 30 and the water from the coalescer contained in the coalescer line 42 is sent to the process water stripper 50 . The process water stripper 50 purifies the process water by removing hydrogen sulfide, carbon dioxide, ammonia, and light hydrocarbons. The gases contained in the gas line 54 are typically sent to the quench water tower 20 and the bottoms contained in the process water stripper line 52 from the process water stripper 50 are sent to the dilution steam generator 60 . Dilution steam makeup 56 can be added to the process water stripper 50 as needed. The dilution steam generator 60 generates dilution steam using quench oil or medium pressure steam. The steam drum in the dilution steam generator 60 contains a demister pad to eliminate carry over of impurities and the impurities are purged via the blow down 64 . The treated dilution steam 62 is directed to the feed line 10 to recycle dilution steam back into the pyrolysis furnace 12 .
[0026] The neutralizing agent can be injected at one or more points within the dilution steam system for ethylene production. The neutralizing agent can be injected into the process water stripper line between the process water stripper and the dilution steam generator at a concentration to keep the aqueous solution in the dilution steam generator at a pH between about 9 and about 12, preferably between about 9.5 and about 10.5, thereby reducing corrosion or fouling of the dilution steam generator. For example in FIG. 1 , an injection of the neutralizing agent into a dilution steam generator injection point 58 into the process water stripper line 52 can be made to maintain the pH of the aqueous solution in the dilution steam generator 60 at between about 9 and about 12, preferably between about 9.5 and about 10.5.
[0027] The neutralizing agent can be injected into the quench water tower line between the quench water tower and the quench water separator at a concentration to keep the aqueous solution in the quench water separator at a pH between about 5.5 and 7.5, thereby reducing corrosion of the quench water separator. For example in FIG. 1 , an injection of the neutralizing agent at a quench water separator point 28 into the quench water tower line 22 can be made to provide the aqueous solution in the quench water separator 30 with a pH between about 5.5 and about 7.5.
[0028] The neutralizing agent can be injected into the quench water separator line between the coalescer and the process water stripper at a concentration to keep the aqueous solution in the process water stripper at a pH between about 8 and 9, thereby reducing corrosion or fouling of the process water stripper, and reducing ammonia contamination of the vapor exiting the process water stripper. For example in FIG. 1 , an injection of the neutralizing agent at a process water stripper injection point 48 into the coalescer line 42 can be made to maintain the aqueous solution in the process water stripper 50 at a pH between about 8 and about 9.
[0029] Another aspect of the invention is a method for inhibiting fouling and corrosion of equipment in an ethylene production plant. The method comprises injecting a neutralizing agent comprising a choline salt into a dilution steam system. The dilution steam system comprises a furnace, a quench water tower, a quench water separator, a coalescer, a process water stripper, and a dilution steam generator and the neutralizing agent is injected (i) into a process water stripper line between the process water stripper and the dilution steam generator at a concentration to keep the aqueous solution in the dilution steam generator blowdown at a pH between about 9 and about 12, thereby reducing corrosion or fouling of the dilution steam generator; (ii) into a quench water tower line between the quench water tower and the quench water separator at a concentration to keep the aqueous solution in the quench water separator at a pH between about 5.5 and 7.5, thereby reducing corrosion of the quench water separator; and (iii) into a coalescer line between the coalescer and the process water stripper at a concentration to keep the aqueous solution in the process water stripper bottom discharge at a pH between about 8 and 9, thereby reducing corrosion or fouling of the process water stripper, and reducing ammonia contamination of the vapor exiting the process water stripper.
[0030] A method of the invention inhibits fouling and corrosion of equipment in a styrene production plant and comprises injecting a neutralizing agent into a dilution steam system, the neutralizing agent having a volatility index of less than 0.005 and a pKa of about 12 to about 20, and being substantially sodium-free.
[0031] A method for inhibiting fouling and corrosion of equipment in an styrene production plant, the method comprising injecting a neutralizing agent into a dilution steam system, the neutralizing agent comprising a choline salt stabilized by about 2 wt. % to about 10 wt. % alkanolamine.
[0032] A representative dilution steam system for styrene production is shown in FIG. 2 , in which an ethyl benzene feedstock in a feed line 106 is mixed with superheated steam from a superheater line 112 and fed via line 108 to a reactor 120 and reacted. The effluent from the reactor contained in a reactor line 122 is directed to a series of heat exchangers (e.g., heat exchanger 130 , heat exchanger 134 , and heat exchanger 138 ) to cool and condense the reactor effluent. The contents of heat exchanger 130 are directed to heat exchanger 134 through heat exchanger line 132 , the contents of heat exchanger 134 are directed to heat exchanger 138 through the heat exchanger line 135 . The contents of heat exchanger 138 are transferred through the heat exchanger line 139 to the separator 140 , which separates vent gas from condensate and crude styrene. The vent gas from the separator 140 is directed through the vent gas line 142 to a gas/liquid separator 150 and the vent gas from the vent gas condenser is directed through a vent gas condenser line 154 to a vent gas compressor 156 . The compressed vent gas is directed through a compressor line 157 to a compressor heat exchanger 158 and sent as an off gas through the off gas line 159 .
[0033] The condensate from the separator 140 is directed through the separator line 146 to the process water stripper 160 . The process water stripper bottoms are directed through a process water stripper line 162 to a dilution steam generator 170 . The steam from the dilution steam generator 170 can be directed through a dilution steam generator line 176 to a superheater 110 . The steam released from the superheater 110 is directed through a superheater line 112 into the reactor 120 to react with the ethyl benzene.
[0034] The neutralizing agent can be injected at one or more points within the dilution steam system for styrene production. A neutralizing agent can be injected into a heat exchanger line between two heat exchangers at a concentration to keep the condensate from the separator at a pH between about 6.5 and about 7.5, thereby reducing corrosion or fouling of the heat exchanger or separator. For example in FIG. 2 , an injection of neutralizing agent can be made into the heat exchanger line 135 at heat exchanger injection point 136 to maintain the aqueous solution in the separator 140 at a pH between about 6.5 and about 7.5.
[0035] Further, a neutralizing agent can be injected into a vent gas line between the separator and the vent gas condenser at a concentration to keep vent gas condenser condensate at a pH between about 6.5 and 7.5, thereby reducing corrosion of the vent gas compressor. For example in FIG. 2 , a neutralizing agent can be injected into the vent gas line 142 at vent gas injection point 144 to maintain the pH of the condensate in the vent gas condenser 150 at a pH between about 6.5 and 7.5.
[0036] Additionally, a neutralizing agent can be injected into a separator line between the separator and the process water stripper at a concentration to keep the aqueous solution in the process water stripper bottoms at a pH between about 8.8 and 9.2, thereby reducing corrosion or fouling of the process water stripper, and reducing ammonia contamination of the vapor exiting the process water stripper. For example in FIG. 2 , a neutralizing agent can be injected into the separator line 146 at a separator line injection point 148 to maintain the pH of the aqueous solution in the process water stripper 160 is from about 8.8 to about 9.2.
[0037] Also, a neutralizing agent can be injected into a process water stripper line between the process water stripper and the dilution steam generator at a concentration to keep the dilution steam generator blow down at a pH between about 9.5 and 10.5, thereby reducing corrosion of the dilution steam generator. For example in FIG. 2 , an injection of the neutralizing agent can be made into the process water stripper line 162 at a process water stripper injection point 164 to maintain the pH of the aqueous solution in the dilution steam generator 170 at a pH from about 9.5 to about 10.5.
[0038] Another aspect of the invention is a method for inhibiting fouling and corrosion of equipment in a styrene production plant. The method comprises injecting a neutralizing agent comprising a choline salt into a dilution steam system, wherein the dilution steam system comprises a super heater, a reactor, a plurality of heat exchangers, a separator, a vent gas condenser, a vent gas compressor, a process water stripper, and a dilution steam generator and wherein the neutralizing agent is injected (i) into a heat exchanger line between two heat exchangers at a concentration to keep the condensate from the separator at a pH between about 6.5 and about 7.5, thereby reducing corrosion or fouling of the heat exchanger or separator; (ii) into a vent gas line between the separator and the vent gas condenser at a concentration to keep vent gas condenser condensate at a pH between about 6.5 and 7.5, thereby reducing corrosion of the vent gas compressor; (iii) into a separator line between the separator and the process water stripper at a concentration to keep the aqueous solution in the process water stripper bottoms at a pH between about 8.8 and 9.2, thereby reducing corrosion or fouling of the process water stripper, and reducing ammonia contamination of the vapor exiting the process water stripper; and (iv) into a process water stripper line between the process water stripper and the dilution steam generator at a concentration to keep the dilution steam generator blow down at a pH between about 9 and about 12, preferably between about 9.5 and about 10.5, thereby reducing corrosion of the dilution steam generator.
[0039] The relationship between corrosion control and operating pH is straight forward: acidic pH conditions are corrosive, while alkaline conditions cause less corrosion. The relationship between pH control and fouling is not as straightforward. For the ethylene cracking process, high pH in the quench water tower and oil/water separator increases the formation of stable hydrocarbon/water emulsions. The composition of pyrolysis gasoline can contain numerous reactive olefins and diolefins that are prone to polymerization reactions. The process conditions and reactants in the process water stripper can promote polymerization while solvent removal from emulsions not resolved in the oil/water separator takes place. In turn, this polymer production and solvent removal can lead to foulant (e.g., hydrocarbon polymers) deposition in the bottom of the process water stripper and in the dilution steam generator.
[0040] When traditional amines, most often alkanolamines, are used as steam dilution system neutralizing agents, the initial control of quench water pH poses no problems. However, during and after this initial period of operation, a small amount of amine can travel with the dilution steam and can be pyrolyzed in the furnace, thus generating ammonia. Since ammonia is a volatile alkalizing agent, when formed, it accumulates in the quench water tower and in the oil/water separator. This ammonia accumulation causes the quench water pH to rise above the desired pH set point and the elevated pH promotes the formation of stable emulsions. When the ammonia accumulation exceeds the saturation limits of the quench water system, the ammonia can travel with the cracked gas towards the purification system. The ammonia distills with the ethylene fraction and can contaminate the final product. Thus, providing controls for the ammonia produced in the ethylene process is advantageous.
[0041] The volatility index (or V/L ratio) of the neutralizing agent is the measure of the partition of the neutralizing agent between the vapor and liquid state at a particular pressure. The volatility index is determined by operating a small boiler unit. The boiler is charged with de-ionized water and a measured amount of the neutralizing agent is added to the water. The boiler is heated to a specified pressure and when steady-state at that pressure is achieved, a sample of steam is condensed and collected and simultaneously a sample of the boiler water is collected. The two water samples are then analyzed for the neutralizing agent concentration. The volatility index is then calculated by dividing the concentration of the neutralizing agent in the steam by the concentration of the neutralizing agent in the water. Then, the boiler is heated further to the next desired pressure and when steady-state is achieved, another set of samples is collected.
[0042] The neutralizing agent can comprise a choline salt. Preferably, the choline salt is choline hydroxide.
[0043] When the neutralizing agent is a choline salt, the choline salt can be advantageously stabilized to provide a stabilized choline composition comprising a choline salt, a solvent, and from about 2 wt. % to about 10 wt. % of an alkanolamine based on the total weight of the composition.
[0044] The stabilized choline composition can have a concentration of choline salt from about 10 wt. % to about 50 wt. %, from about 15 wt. % to about 30 wt. %, from about 15 wt. % to about 25 wt. %, or about 20 wt. % based on the total weight of the composition.
[0045] The stabilized choline composition can comprise an alkanolamine such as methanolamine, ethanolamine (i.e., monoethanolamine (MEA)), propanolamine, butanolamine, or a combination thereof. Preferably, the alkanolamine is methanolamine, ethanolamine, or a combination thereof. More preferably, the alkanolamine comprises ethanolamine (MEA).
[0046] The stabilized choline composition can comprise the alkanolamine in a concentration from about 3 wt. % to about 8 wt. %, about 4 wt. % to about 6 wt. %, or about 5 wt. % based on the total weight of the composition.
[0047] The solvent in the stabilized choline composition can comprise water.
[0048] In operational practice, an ethylene plant is a dynamic process with minor shifts in feedstock composition, process flow rates, temperature fluctuations, and other process conditions and as a result, the concentration of acids to be neutralized is can vary slightly. The preferred, stabilized neutralizing agent of this invention is additionally advantageous because the relationship between the pH of the solution and the concentration of neutralizing agent used (i.e., the neutralization profile) goes from a nearly vertical rise in pH at pHs of 9 and below to a less steep pH rise when concentration of the neutralizing agent keeps the solution between pH 9 to 12, preferably, between pH 9.5 to 10.5. This pH target of 9 to 12, preferably, pH 9.5 to 10.5 is sought in the dilution steam generator, where corrosion is the greatest concern. This neutralizing profile for the neutralizing agent described herein means that less of the neutralizing agent is needed to maintain the solution it is used to neutralize (e.g., dilution steam) at the desired pH.
[0049] The neutralizing agent can be injected into the system in a variety of ways known to a person of skill in the art. The injection control may be a microprocessor, a central process unit, or any other similar device capable of processing the signal output from the acid measurement device and controlling the rate of dispensation of the neutralizing agent in response to this signal. The injection control may be integral with the neutralizing agent injector or it may be separate. Suitable injection controllers would include control systems that are well known in the art.
[0050] The acid concentration detector may be any one of a number of devices capable of generating a signal responsive to the concentration of acid in the dilution steam system. Automated titrators are particularly effective acid measuring devices. A number of automated titrators suitable for use in the system are commercially available including those from Rosemount Inc., Honeywell, Hach, or Mettler Toledo.
[0051] Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.
EXAMPLES
[0052] The following non-limiting examples are provided to further illustrate the present invention.
Example 1
Titration of 1300 Ppm of Acetic Acid with Neat Ethanolamine (MEA)
[0053] To test the comparative neutralization efficacy of MEA as a neutralizer, the solution was initially diluted according to the following procedure. Into a glass container was added 10.0 g of neat MEA. This was diluted to a total mass of 500 g using deionized water.
[0054] A solution of 1300 ppm acetic acid was prepared by adding 0.652 g of 99.7% (purity) glacial acetic acid to a 500 mL volumetric flask. To this flask was added deionized water to give 500 mL of final solution. A 30 mL aliquot of this solution was added to a 100 mL titration vial. Using a pH meter, the initial pH of this solution was measured. Thereafter, the diluted solution of neat MEA was added to the vial in small quantities at a time while the pH of the solution was measured at every point. The titration was continued until the solution had the target pH of 10.5. To reach this pH, 8154 ppm of the neutralizer was required.
Example 2
Titration of 1300 Ppm of Acetic Acid with Choline Hydroxide
[0055] In the second example of comparative neutralization, 45% (w/w) choline hydroxide was initially diluted prior to the titration with 1300 ppm of acetic acid according to the procedure in Example 1. The titration was continued until the solution had the target pH of 10.5; 4820 ppm of the neutralizer was required to reach this pH.
Example 3
Boiler-MEA Formulation Neutralization of Acetic Acid
[0056] At the temperature at which the ethylene plant boiler is operated, MEA is volatile such that a third of the neutralizer evaporates before neutralizing the acids in the water. To mimic the concentration of the MEA left in the boiler, a formulation containing 66.4% (w/w) of MEA and 33.6% (w/w) deionized water was prepared. This formulation was used to neutralize 30 mL of 1300 ppm acetic acid following the procedure in Example 1. To reach the target pH of 10.5, a total amount of 9792 ppm of the neutralizer formulation was added to the acetic acid solution.
Example 4
Titration of 1300 Ppm of Acetic Acid with Heavy Neutralizer Formulations
[0057] Heavy neutralizer formulations were prepared by blending MEA with 45% (w/w) choline hydroxide. By way of example, the heavy neutralizer formulation was prepared by adding 3 g of ethanolamine (MEA) to a glass bottle containing 97 g of an aqueous solution of 45% (w/w) choline hydroxide. This contained 3% (w/w) of MEA and 43.4% % (w/w) of choline hydroxide solution. As in Example 1, 10 g of this neutralizer was initially diluted with deionized water yield a total mass of 500 g.
[0058] The same stock solution of 1300 ppm acetic acid prepared in Example 1 was used for the titration with the diluted solution of the heavy neutralizer comprising 3% (w/w) MEA and 43.4% (w/w) of choline hydroxide. Similar to Example 2, the diluted solution of the heavy neutralizer formulation was added in small quantities while monitoring the pH of the solution after each addition of the neutralizer until the pH of the solution was basic and the pH plateaued off. A total concentration of 4846 ppm of this heavy neutralizer was consumed to attain the pH of 10.5.
[0059] Other formulations were similarly prepared, diluted and titrated against 1300 ppm of acetic acid. The formulation compositions and concentrations required to reach the pH condition of 10.5 are shown in the table below. Titration curves of some of the formulations are shown in FIG. 3 .
[0000] Heavy neutralizer formulations and amount (ppm) required to keep a solution of 1300 ppm acetic acid at a pH of 10.5.
[0000]
% (w/w)
% (w/w)
ppm of Base
MEA
Choline Hydroxide
(to keep pH of 10.5)
100
0.0
8154
66.4*
0.0
9792
30.0
31.9
5434
12.0
39.6
5080
9.0
41.0
5167
6.0
42.3
4868
3.0
43.4
4846
0.0
45.0
4820
*Percentage of MEA in boiler after the evaporation of some of the injected MEA.
Example 5
Stability of Treated and Untreated Choline Hydroxide Solutions Stored at Room Temperature
[0060] To a sample of 96 g aqueous choline hydroxide solution (20.3 wt. %) was added 4.0 g ethanolamine. No ethanolamine was added to a second sample. The samples were stored in a fume hood at 25° C. for a period of approximately 12 months. The decomposition of the samples over time was monitored using a spectrophotometer (λ max =410 nm). Upon decomposition, the initial colorless solutions of choline hydroxide turned yellow; as decomposition progressed, the solutions turned brown. In addition to the change in color, the decomposition process resulted in the formation of suspended, and then settled solids.
Example 6
Stability of Treated and Untreated Choline Hydroxide Solutions Incubated at 55° C. For 397 Days
[0061] To a sample of 96 g aqueous choline hydroxide solution (20 wt. %) was added 4.0 g ethanolamine. To a second sample no MEA was added. An additional untreated sample of aqueous choline hydroxide (45 wt. %) was also prepared. The three samples were then incubated at a temperature of 55° C. for a period of 397 days.
[0062] After 397 days, the three samples were removed from the incubator and visually inspected. The untreated 45 wt. % choline hydroxide sample had a brown supernatant and brown sediment at the bottom of the container. The untreated 20 wt. % choline hydroxide sample also had a brown supernatant but less brown sediment was observed. The treated 20 wt. % choline hydroxide sample did not have any sediment, and was pale amber in color.
[0063] Using a spectrophotomer, undiluted aliquots of the treated and untreated 20 wt. % choline hydroxide solutions were analyzed for decomposition at an absorbance of 410 nm. Absorbance of the treated sample was 2.850, whereas absorbance of the untreated sample was 3.315. Additional absorbance measurements were then taken using 0.5 mL aliquots of each sample that had been diluted with 9.5 mL of deionized water. Absorbance of the treated diluted sample was 0.380, and absorbance of the untreated diluted sample was 0.786.
Example 7
Stability of Treated and Untreated Choline Hydroxide Solutions Incubated at 55° C. For 20 Days
[0064] A stock solution of aqueous choline hydroxide (20.83 wt. %) was prepared by dilution of 40.195 g aqueous choline hydroxide solution (45 wt. %) with 48.552 g deionized water. To a sample of 24.0 g of the stock solution was added 1.0 g ethanolamine. To a second sample of 24.0 g of the stock solution was added 1.0 g deionized water. The samples were then incubated at 55° C. At intervals, 0.5 mL aliquots of each sample were retrieved and diluted with 9.5 mL deionized water, then their absorbance measured at λ max =410 nm. Aliquots were taken at T=0, 3, 8, 10, 16, and 20 days. The absorbance data for the treated and untreated samples of aqueous choline hydroxide solution as a function of time is shown in the table below.
[0000]
Incubation
20% Choline
20% Choline
Days
Bases (Untreated)
Base (Treated)
0
0.004
0.004
3
0.016
0.008
8
0.048
0.019
10
0.053
0.02
16
0.063
0.033
20
0.088
0.042
397
0.786
0.380
[0065] When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
[0066] In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
[0067] As various changes could be made in the above compositions and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | The present invention generally relates to compositions and methods for neutralizing acidic streams in an olefin or styrene production plant. More specifically, the invention relates to neutralizing agents for dilution steam systems in the steam cracker process and their use for reducing acid corrosion and fouling in such systems. | 2 |
RELATED PATENT APPLICATIONS
This application is a continuation-in-part of applicants' earlier filed application Ser. No. 314,179, filed Feb. 22, 1989, now abandoned.
FIELD OF THE INVENTION
This invention relates to the presentation of patients for surgical and investigative procedures, especially but not solely for renal endoscopic procedures, and is particularly concerned with a wheelchair in which a patient can be sat and subsequently presented in a suitable position for a surgical or investigative procedure. The invention is also concerned with a surgical or investigative work station at which a surgeon may be seated and at which a patient in the wheelchair can be presented for a surgical or investigative procedure.
BACKGROUND OF THE INVENTION
While many surgical and investigative procedures involving the use of endoscopes inserted through a natural orifice or a percutaneous access site may take only a short time to conduct, a considerable amount of time is taken in removing the patient from a hospital trolley and placing him or her on an operating surface and then reversing this procedure at the end of the surgery or investigation. Indeed, up to 70% of the time may represent patient handling and only 30% is devoted to the surgical or investigative procedure.
BRIEF SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided a wheelchair comprising
a frame,
wheels on said frame,
a back rest portion mounted on said frame for pivotal movement from a normal upright inclined position to a substantially horizontal position,
a central seat portion pivotable about a horizontal axis located adjacent the lower end of the back rest portion,
two outer seat portions arranged one on each side of said central seat portion,
means pivotally supporting said outer seat portions for movement toward and away from said central seat portion about axes located near the back rest portion,
two foot rests, and
means supporting a foot rest and attaching it to a respective outer seat portion, the wheelchair being disposed such that a patient can be received in the wheelchair in a semi-recumbent position and the back rest portion and seat portions can be tilted to present the back of a patient in a horizontal position with the patient's legs at a higher level than the patient's head, whereafter the central seat portion can be pivoted downwardly and the outer seat portions pivotted outwardly to present the patient in a position for an ano-reno-genito surgical or investigative procedure.
Each outer seat portion and an associated foot rest attached thereto may constitute a leg support portion with the attachment of the foot rest to the seat portion lying at an obtuse angle to the underside of the seat portion.
Because the back rest portion and the foot rest attachment both lie at an obtuse angle to the seat portion, the position of the patient relative to these portions does not substantially alter when the patient is tilted from a normal semi-upright or rest position into the operative position. The obtuse angles which the back rest portion and foot rest attachment make with the seat portion will normally lie within the range of 100° to 140°. It may be desirable to make the back rest portion and foot rest means adjustable relative to the seat portion so that the angles and positions can be adjusted to accommodate patients of different sizes or proportions, but in most cases such adjustment will be unnecessary and a similar effect might be obtained, for instance, by placing a small cushion in the small of the patient's back.
The arrangement and disposition of the wheels, by which the wheelchair is mobile, may take many forms. In one embodiment, a pair of large diameter wheels is mounted on an axle beneath the seat portion so as to constitute a wheeled frame and the wheels may have hand rings whereby the patient can propel the wheelchair. In this case, a stabilizing wheel or wheels is or are provided and may conveniently be arranged on an arm which depends below the back rest portion and can be folded up to the back rest portion when the chair is tilted into the operative position. The arm, in its folded position, may act as a rest or stop holding the back rest portion in the substantially horizontal operative position or a separate rest or stop may be provided. In a preferred embodiment the back rest portion has attached to it a handle by which a hospital porter or nurse can move the wheelchair and this handle may act as a rest or stop for the backrest portion in the operative position.
In another embodiment of the wheelchair, the chair portions are pivotally mounted on a wheeled undercarriage so that the chair can be tilted from the rest position to the operative position. Preferably means are provided for locking the chair in each of these positions.
If the present chair is to be used in ano-reno-uro-genito-endoscopic procedures, it is necessary to present the patient to the surgeon with the legs of the patient wide apart and with a space between them so that the surgeon can approach the patient. To this end the outer seat portions and associated foot rests are pivotally mounted so that when the chair is in or being moved into the operative position the patient's legs can be parted. The wheelchair may be equipped with means for spreading the outer seat portions apart. The means for spreading the supports apart may be manually operated and include a hand lever or hand wheel, or in a more sophisticated embodiment a lever system may be provided for automatically spreading the outer seat ports apart as the wheelchair is moved from the rest position to the operative position. However, in this case it is desirable to have a manual override to prevent undue stress on elderly patients or patients with no or with restricted hip mobility.
Since it is the intention that the present wheelchair will be used to wheel a patient from a ward or waiting area to an operating or investigating station, it is clear that the wheelchair will not be sterile. Nevertheless, it is important that the wheelchair and in particular the chair portion supporting a patient should be made of or covered with materials which are capable of withstanding washing with disinfectants. Preferably, the wheels and framework of the wheelchair are made of aluminum alloys or even stainless steel, and the chair portions are covered with rubber or plastics, which can be washed with disinfectants, even though the patient will normally sit on a washable or disposable cover laid on the chair.
In the use of the chair, a patient is placed on the chair either in a hospital ward, or, if the patient is an ambulant day-patient, in a waiting area, and is then wheeled to an operating station. On arrival at the operating station, the wheelchair is tilted and the patient is presented to the surgeon in the correct position for an endoscopic surgical or investigative procedure to be carried out. At the end of the procedure, the chair is tilted back to the semi-recumbent rest position and wheeled away, whereupon the next patient can be wheeled up to the operating station so that there is no waste of the surgeon's time at the operating station.
It will be appreciated that apart from operations and investigations conducted in the ano-genital area of a patient, similar endoscopic investigations and operations can be conducted at the head and chest of a patient. Of course, in conducting the latter procedures it is not necessary for the patient's legs to be spread apart and in consequence a simpler version of the wheelchair is suitable for such procedures. In an alternative embodiment of the wheelchair, the back rest portion, seat portion and a leg support portion or portions are mounted so that they can lie substantially flush with one another so as to provide a flat surface to receive a patient in a prone position.
As just indicated, the purpose of the wheelchair is to present the patient at an operating station where operative and investigative procedures can be carried out. It is a further and concomitant object of the present invention to provide such an operating station.
Accordingly, a further aspect of the present invention provides an operating station at which operative or investigative procedures can be carried out on a patient, comprising means to accommodate a surgeon in a sitting position, a work table in front of said means, a first work station to one side of said means for receiving sterile instruments and materials for use in an operative or investigative procedure, a second work station to the other side of said means for receiving used instruments and materials, and means for receiving the present wheelchair the work table and work stations being so shaped and located that when the wheelchair indicated above is wheeled up adjacent the station, the region of the patient to be operated on or investigated is presented at said work table.
Thus, when the ano-genital region of a patient is to be operated on or investigated, that region will be presented at the work table and the surgeon will be seated with the patient's legs on each side of him, the work table being appropriately shaped to lie between the two leg supports of the wheelchair.
In order to present the patient at the right height to the surgeon it may be necessary either to use a split-level operating theatre or to sit the surgeon in a well. However, a more convenient arrangement will be to provide a hydraulic or other lift to which the wheelchair can be firmly attached and then raised to the correct height for the appropriate procedure.
With the present operating station and wheelchair, a surgeon sitting at the operating station can carry out a large number of operative or investigative procedures in a fraction of the time normally entailed in such procedures, most of which is represented by the time taken to remove the patient from a hospital trolley to an operating surface and back again.
Thus with the present invention, the surgeons time is more usefully employed, as are expensive hospital resources, with a consequent reduction in hospital waiting lists.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified schematic representation (side view) of a wheelchair in accordance with the invention;
FIG. 2 is a perspective view of a first embodiment of a wheelchair in accordance with the invention;
FIG. 3 is a side view of the wheelchair of FIG. 2 showing the mechanism by which the seat can be swung and locked in different positions;
FIG. 4 is a further perspective view of the wheelchair of FIG. 2 showing how the seat is mounted for pivotal movement on the wheeled frame;
FIG. 5 is a perspective view of the wheeled frame of the wheelchair of FIG. 2;
FIG. 6 is a front view of the wheelchair of FIG. 2, with the seat in position for an investigative or operative procedure;
FIG. 7 is a rear view of the wheelchair of FIG. 2, with the seat in an upright position;
FIG. 8 is a side view of a caster wheel of the wheelchair of FIG. 2;
FIG. 9 is a sectional view of the locking and release means for pivotal movement of the seat of the wheelchair of FIG. 2;
FIG. 10 is a sectional view of the locking and release means for the side portions of the seat of the wheelchair of FIG. 2;
FIG. 11 is a perspective view of a detail of the wheelchair of FIG. 2 for use during an emergency;
FIG. 12 is a diagrammatical plan view of an operating station, and
FIG. 13 shows how the structure of FIG. 9 is used to lower the patient's head during an emergency.
DETAILED DESCRIPTION OF THE INVENTION
The basic principle of the wheelchair of the present invention will first be described with reference to FIG. 1 which is a diagrammatic representation of a patient in a wheelchair. The wheelchair shown in FIG. 1 comprises a back rest portion 1, a seat portion 2 and two leg supports 3. The back rest portion 1 lies at an obtuse angle of about 130° to the seat portion 2 and the leg supports 3 also lie at an obtuse angle of about 130° to the seat portion. Because of these angles, the patient 4 is presented in the wheelchair in a semi-recumbent and relaxed position. The wheelchair has a pair of large diameter wheels 5 mounted on an axle 6 beneath the seat portion and the wheels may have hand rings whereby the patient can propel the chair, although these will generally be unnecessary. A stabilizing wheel or wheels is or are provided for the wheelchair but not shown in the drawing. A stabilizing wheel may be arranged on an arm which depends below the back rest portion and which can be folded flat against the back rest portion when the chair is tilted into an operative position, or stabilizing wheels may be arranged on an axle mounted below the leg supports 3.
The back rest portion 1 is provided with a handle 7 by means of which a hospital porter or nurse can hold the wheelchair to move it and the handle can act as a rest or stop in the operative position. In addition arm rests 8 for the patient may be provided.
In the use of the wheelchair, the patient is placed in the chair or enters it by himself if ambulant and, after the administration of any necessary pre-operative medication, is wheeled to the location where the endoscopic procedure is to be carried out. The chair is then tipped so that the handle is on the ground, i.e. so that the broken line 9 is the ground. The patient is then presented in an appropriate position for the endoscopic procedure, with his head and back horizontal and his legs raised. The patient's legs can then be moved apart to permit the surgeon to operate.
A practical version of a wheelchair in accordance with the invention will now be described with reference to FIGS. 2 to 9. Although FIG. 2 is a perspective view of the wheelchair, because of the manner in which the wheelchair is constructed, no one view can begin to show all the features of the wheelchair. The wheelchair will therefore be described with reference to several views of the wheelchair which can be clearly related to one another. In each view, several parts of the wheelchair are omitted so as to prevent them from obscuring the view, the omitted parts, however, being shown in another view. Thus, FIG. 3 shows a wheeled frame for the wheelchair, while FIG. 2 shows the seating and patient-receiving parts of the chair in relation to the wheeled frame. FIGS. 4 and 5 show detailed views of the mechanisms by which the seating and patient receiving parts of the chair can be arranged in different configurations and show the relationship of these mechanisms to the wheeled frame. FIGS. 6 to 9 show further details of the wheelchair.
Referring now to FIG. 2, there is shown the seating part of the chair, that is to say, the part for receiving a patient, this part being mounted on a wheeled frame shown in FIG. 3.
The wheelchair comprises a back rest portion 10, the sides 11 of which are rounded outwardly to give side support to a patient. Two arm rests 12 are provided below the sides 11 and are shown in position to receive the arms of a patient sitting in the chair. Each arm rest 12 can be folded to lie flat against a board 13 forming part of a support structure for the back rest portion the arm rests in their folded position lying flush with the lower part of the back rest portion.
The wheelchair also has a seat portion which is divided into a central portion 14 and two side portions 15. The central portion 14 is carried by two arms 114 which are mounted on a rod 115 rotatably mounted in brackets 116 of a support structure to be described, so that the central portion can be swung about the axis of the rod 115 (c.f. FIG. 5). Each of the side portions 15 has an arcuate retaining board 16 to prevent the legs of a patient from slipping outwardly off the seat. Each side portion 15 has a square section bar 17 attached to it and each bar has a foot rest 18 mounted on it so as to be adjustable up and down. The bars 17 will normally extend forward of the seat portion with the foot rests raised above the ground. However, the bars are mounted beneath the side portions 15 so that they can be moved into a position where they extend substantially vertical so that the foot rests can be lowered into contact with the ground to assist the entry of a patient into the wheelchair. The back rest portion 10, the arm rests, the central and side seat portions and the foot supports are padded, where appropriate, and covered with plastics material capable of withstanding being washed with disinfectant. Conveniently, the plastics material may be one which simulates leather.
FIG. 3 shows a wheeled frame for the wheelchair. The frame comprises two substantially D-shaped side members 20 which are joined at the bottom and near the top of the upright portions of the side members by cross-members 21 and 22 and at the bottom by a substantially A-shaped member 23 the apex of which also connects with the lower cross-member 21. At their forward ends the side members 20 have support discs 24 which support stub axles for spoked wheels 25. Outrigger rods 26 attached to the upright portions of the side members 20 carry at their lower ends castor wheels 127 which have foot-operable brake elements 28. Each brake element 28 comprises an upper plate 130 to which is attached a braking block 128 pivoted at 131 in a bracket 27 housing the castor wheel 127. Operation of the brake is by depressing the free end of the upper plate 130 and this causes the braking block 128 to engage the wheel 127 and brake it as shown in FIG. 6. At their uppermost regions, the side members 20 have discs 29 secured thereto and two arms 30 are pivotally mounted on the discs at 129 and hang downwardly. The arms 30 are joined by a member, indicated at 31, which is joined to the support structure for the back rest portion, so that the back rest portion is thereby mounted for swinging movement about an axis joining the pivot points 129 of the arms 30 on the discs 29.
FIG. 4 shows the mechanism by which the chair can be swung and locked in different positions and the mechanisms for enabling the arm rests 12 to be folded and the foot rests to be adjusted. The frames 20 and the member 23 support a cross-beam 32 which has two L-shaped brackets 33 fixed to it in opposition to one another. The brackets define between them a space in the mid-plane of the wheelchair and a quadrant 34 is held securely between the brackets, the quadrant being formed with rectangular recesses 35. The quadrant could also be formed with ratchet teeth.
A wooden support structure for the back rest portion 10 includes two triangular wings 36 which are spaced apart and which are joined at their lower ends by a base board 37 (c.f. FIG. 5). Beneath the base board is a cruciform member 38 one arm 39 of which carries a spring-loaded detent 40 engaging in one of the recesses 35. The detent 40 is held in a T-shaped slot in the arm 39 and has a depending lug 140 received in the stem of the T-shaped slot. The detent 40 is urged into engagement with the quadrant 34 or a recess 35 by a compression spring 141 (c.f. FIG. 7) housed in a recess 139 in the arm 39. A cable connection 41 comprises a sheath 142 held stationary in a block 143 and a wire 144 movable in the sheath by means of a hand lever 42 to which the wire 144 is connected. The hand lever 42 is mounted on a handle 43 by means of which a porter or nurse can move the chair.
By operating the hand lever 42, the wire 144 is moved in the sheath and acts on the lug 140 to retract the detent 40 into the T-shaped slot into the position shown in FIG. 7. This operation moves the detent 40 out of a recess 35 and, in this position, the parts of the chair, comprising the back rest portion 10, the seat portion 14 and 15 and the leg supports 17 and 18, can be swung on the arms 30 and joining member 31 about an axis joining the pivot points 129 until the detent encounters the next recess. Upon release of the hand lever 42, the detent 40 is then urged into the recess 35 by the spring 141 so that the chair will be locked in this position.
As indicated in FIG. 2, the boards 13 are formed with slots 44 and support bars 45 pivotally attached to the undersides of the arm rests 12 pass through the slots where each support bar is held by the engagement of a bayonet slot 46 in the arm 45 and a rod 101 extending across the slot 44. In order to fold the arm rests flat, the bars 45 are lifted to disengage the bayonet slots from engagement with the rods and then the bars 45 are passed through the slots 44 to allow the arm rests to lie flush against the boards.
Each square section bar 17 is formed on its underside with holes 47 (c.f. FIG. 5) and each foot rest 18 has attached to it a locking mechanism 48 which comprises a spring-loaded pin engaging in a hole 47 in the bar 17 and thus locking the foot rest in position. A handle 49 of the locking mechanism can be operated to retract the pin and allow the foot rest to be moved up or down the bar to adjust the foot rest to the required position for a patient.
Beneath each side seat portion 15 is a support structure of bars which extend below the base board of the wooden support structure. One of these bars 50 for each side seat portion carries a hand lever 51 for operating a cable connection comprising a sheath 150 held stationary in a block 151 and a wire 152 movable in the sheath by the hand lever 51, as shown in greater detail in FIG. 8.
Each side seat portion 15 has mounted beneath it a hollow beam 52 within which is a rod 153 acting as a detent. Each rod 153, as shown in FIG. 8, has a pointed end 53 which engages in a toothed quadrant 54, two such quadrants being mounted below the base board.
Each rod 153 is urged by a spring 154, housed in the hollow beam 52, into engagement with the toothed quadrant. However, operation of the hand lever 51 causes the wire 152 to be moved in the sheath 150 so as to pull the rod 153 against the action of the spring 154 so as to retract the pointed end 53 of the rod from engagement with the quadrant 54. This allows the side seat portion 15 and foot rest 18 to be swung from a closed position, as shown in FIG. 2 where the side seat portions 15 abut against the central seat portion 14, to an open position as shown in FIG. 5, and vice versa.
Underneath the central seat portion 14 there is a cruciform member 55 which is pivotally mounted on a central pivot 56 and which has two arms 57 which project beyond the seat portion 14 to engage in U-section brackets 58 on the underneath of the side seat portions 15, so as to prevent pivotal motion of one seat portion 14 or 15 in relation to another seat portion. In order to release the seat portions, the cruciform member is pivoted into the position shown in broken lines. The underneath of the central seat portion is also provided with stops 59 and 60 to limit the movement of the member 55 and with guideways 61 for controlling the movement of the ends of the other two arms.
The square section bars 17, on which the foot rests 18 are mounted, are normally held in the forward position shown in FIG. 4 by the engagement of a recess in a bar 62 in a bolt projecting through the bar 17, the bar 62 being urged into such engagement by a spring 63. By disengaging by hand the bar 62, the bar 17 can be moved into the vertical in FIG. 4 to facilitate entry into the wheelchair as will already described.
In operative procedures carried out under anaesthetic where the patient is in a recumbent position, it would be desirable in an emergency to be able to lower the patient's head below the rest of his body so as to prevent, for example, the patient from swallowing or inhaling his own vomit. Therefore in a modification of the wheelchair a frame comprising two uprights 64 and a cross-beam 65 is pivotally mounted to the rear of the two D-shaped side members 20 as shown in FIG. 9. The frame is normally held in the position shown by a spring 66, one end of which is looped over the cross-beam 65 and the other end of which is looped over a convenient fixed point, such as the cross-bar of the A-shaped member 23. When the wheelchair is in the recumbent or operating position, the back of the back rest portion will rest against the upper ends of the uprights. However, in an emergency an anaesthetist can grab the cross-beam 65 and pull it against the action of the spring 66 thereby pivoting the uprights 64 about their pivotal connections 67 to the members 20 an lowering their upper ends. This allows the back rest portion to pivot to lower the head of the patient and the pivotal movement may be as much as 15°.
In the use of the wheelchair, each of the bars 17 is moved from the position shown in FIG. 4 into a position where it extends substantially vertically by disengaging the recess in the bar 62 from the bolt projecting through the bar 17 so that the bar can swing about a pivot 100 under the influence of gravity. The handle 49 is operated to retract the locking mechanism 48 from engaging in a hole 47 so that the foot rest can be moved down the bar 17 into contact with the ground.
A patient then enters the wheelchair and when he or she is settled, the foot rests are raised to the correct level to accommodate the patient's feet and the bars 17 are moved into their forward positions in which they are locked by engagement of the recesses in the bars 62 with the bolts.
The chair is then wheeled to the operating theatre. The hand lever 42 is operated to move the cable connection 41 which acts on the detent 40 to retract the detent from engagement in the recess 35. The whole seat portion can then be swung by hand about the pivot axes of the arms 30 on the discs 29 until the back rest portion 10 lies substantially horizontal, whereupon the hand lever 42 is released and the detent 40 enters the recess 135 shown in FIG. 4. The bayonet slots 46 are then released from engagement with the rods 101 and the arm rests 12 are folded flush with the back rest portion.
The cruciform member 55 which is pivotally mounted beneath the central seat portion 14 is then swung about its pivot 56 to release the ends of the arms 57 from engagement with the U-section brackets 58 on the underside of the seat portions 15 so that the central seat portion can be lowered by being swung about the axis of the rod 115.
The hand levers 51 are then operated and each lever acts on the cable connection shown in FIG. 8 to withdraw the pointed ends of the rods 53 from the teeth of the quadrants 54 so that the side seat portions can be swung outwardly about pivot joints 104. The patient's legs are thus spread apart and the patient is now presented in the correct position for a surgical or investigative procedure.
At the end of the procedure, the side seat portions 15, bars 17 and foot rests 18 are swung back to their original position, the central seat portion 14 is raised and locked in position, and the chair is then moved to raise the patient from a recumbent position to an upright sitting position, all following the reverse of the procedures just described. The patient is then wheeled away.
It is to be appreciated that many other modifications of the wheelchair and its construction are possible and that alternative mechanisms to those described can be provided for moving or permitting movement of the various parts of the seating arrangement. For example, the wheels 25 could be replaced by castors similar to the castors 27, or the wheelchair could be provided with two separate handles for pushing the chair, with the various hand levers for moving the parts of the seating arrangement and for braking mounted on the handles.
While the wheelchair has been shown as having hand levers for moving or permitting movement of the various parts and mechanisms of the wheelchair, it will be appreciated that the various mechanisms can be electronically controlled and in such a case a panel of push buttons or the like will be placed on the handle or in another convenient location.
As clearly shown in FIG. 2, the back rest portion 10 has at its upper end an integral portion against which a patient's head can rest. In a further modification of the wheelchair, this head rest portion can be movable and pivotable about an horizontal axis, there being means to lock the head rest portion in a pivoted position. This enables a patient's head to be raised or lowered (extended), particularly when the patient is in a prone position.
In addition, in a further modification of the wheelchair it is possible to pivot the whole of the seat portion relative to the back rest portion and to move the bars 17 and foot rests 18 so as to provide a flat surface to receive a patient in a prone position.
As indicated above, the wheelchair is particularly suitable for presenting a patient at an operating station at which an operative or investigative procedure can be carried out endoscopically on a patient. Such an operating station is shown very diagrammatically in FIG. 10 and comprises means 70 for accommodating a surgeon in a sitting position with a work station on each side, one for receiving or holding sterile instruments and materials for use in an operative or investigative procedure and the other 72 for receiving used instruments and materials. A work table 73 is provided in front of the surgeon and there is a wheelchair-receiving region 74 at which is means 75 for accommodating an anaesthetist. The arrangement of the seating means, work table and work stations is such that when the wheelchair is brought up to the operating station, the region of the patient to be operated on or investigated is correctly presented at the work table. To this end it may be necessary to seat the surgeon in a well, or to arrange for the wheelchair to be raised either by wheeling it up a ramp to a level position or by elevating the wheelchair as by means of a hydraulic lift. In each case, means is provided for locking the wheelchair adjacent the work table. | In order to present patients in the correct position for surgical or investigative procedures and in order to reduce the time required to place on and remove from operating surfaces on which such procedures are carried out on patients, a wheelchair of novel configuration is described. The wheelchair has a seating arrangement comprising a back rest portion, a seat portion and foot rest means, adapted to receive a patient in a semi-recumbent or sitting position. The seating arrangement can be tilted so that the back rest portion is substantially horizontal and the seat portion is divided so that the patient's legs can be moved apart, while still supported, to present the patient's ano-genital region for surgical or investigative procedures. | 0 |
FIELD OF THE INVENTION
The present invention relates to a system for detecting deflections in a roof structure.
BACKGROUND OF THE INVENTION
As weight accumulates on a roof, especially a large flat roof, that weight deflects the roof's supporting structure. Stress from this weight may eventually cause the roof to collapse, thus causing many potential injuries and even deaths. It would be desirable to be able to monitor and detect these deflections to determine when a roof is in danger of collapse.
Devices for measuring deformations in other structures are discussed in the background of U.S. Pat. No. 5,404,132, which is expressly incorporated herein by reference for all purposes.
SUMMARY OF THE INVENTION
The present invention is a system that can detect weight on a building and can provide an early warning of an impending collapse based on an amount of deflection present in the structure, and is particularly suitable for detecting deflections in joists or structural beams of a roof structure.
In a preferred embodiment of the present invention, an energy beam is directed along a path to a receiver that can sense the energy beam. A target is attached to a roof structure and extends downwardly away from the structure so that the target is in or near the path of the beam and can move respectively out of or into the path in response to a deflection. An alarm connected to the receiver is triggered when the receiver changes state with respect to sensing of the beam. Accordingly, the receiver can trigger an alarm when it receives a beam, while not triggering an alarm when it does not receive the beam, or vice versa. The beam is preferably a pulsed infrared beam, the targets are preferably rectangular plates, and the alarm is preferably triggered by an external edge of the target breaking for a sufficient period of time the beam that otherwise contacts the receiver.
The present invention can provide an early warning that allows a building to be evacuated before it collapses, thus possibly saving lives, particularly in warehouses, supermarkets, superstores, and other large structures with flat roofs. Other features and advantages of the present invention will become readily apparent upon further review of the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of a deflection monitoring system according to the present invention.
FIG. 2 is a diagrammatic side view of the system of FIG. 1.
FIG. 3 is a partial elevated view of a second embodiment of the present invention.
FIG. 4(a) and 4(b) are pictorial views of a target and receiver according to a third embodiment of the present invention.
FIG. 5 is a perspective view of a target according to the present invention.
FIG. 6 is an elevational side view illustrating how a transmitter or receiver is mounted to a roof.
FIG. 7 is a pictorial perspective view illustrating a transmitter, receiver, and targets in a steel roof.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2, in one embodiment of the present invention, a deflection detection system 10 includes an energy beam source 12, a receiver 14, and a number of target blocks 22. The deflection detection system 10 is preferably used on a roof structure 30.
A plurality of sources 12, such as lasers, visible light sources, or infrared light sources (e.g., R Series low power modulated LED infrared light beam sources available from Autotron) are positioned at regular intervals along a perimeter of structure 30. Sources 12 project beams 16 along a path adjacent to the structure 30. Sources 12 are preferably set in series along a side wall (not shown) at the perimeter of the frame of structure 30 to generate beams 16 along a path perpendicular to a set of joists 32 and parallel to support beams 34.
Each beam 16 is directed towards a receiver 14, such as a type produced by Autotron for use with the exemplary infrared source available from Autotron, which is energized when beam 16 strikes receiver 14. Sources 12 and the corresponding receivers 14 are preferably placed a predetermined distance beneath structure 30 and a distance apart, e.g., on the order of hundreds of feet. The sources and receivers 14 may be placed either along opposite side walls, or on independent support columns that would be unaffected by deflection of structure 30. Preferably, however, they are near opposite side walls and are attached to the roof structure itself. Each beam 16 is set to monitor a predetermined zone 26 along the structure in concert with target blocks 22 (shown in more detail in FIG. 5 below). Each receiver 14 is connected to a central alarm 18 that is activated when one of the receivers 14 loses contact with the beam 16. A time for which the beam must be broken to activate the alarm can be variably set in the receiver, e.g., from about 0-3 minutes in single second increments. Alarm 18 preferably signals which zone 26 contains the deflection based on the outputs from the receivers 14.
Target blocks 22 are attached to the structure and normally are disposed along a plane located between the path of beam 16 and the structure. For roof structure 30, target blocks 22 extend downwardly and define a horizontal plane between the roof structure 30 and the horizontal plane defined by beams 16. Target blocks 22 may be of any suitable size or shape. While block 22 is shown with an ellipsoidal shape, it preferably is rectangular. As shown in FIG. 2, when deflection occurs in the structure 30, the lower edge of target blocks 22 move into the path of beam 16. The corresponding receiver 14 outputs this negative condition to alarm 18.
As noted above, deflection monitoring system 10 is preferably used to detect deflections in joists 32 of a roof structure 30. Roof structure 30 includes several sets of joists 32, each of which connects two support beams 34 that span the roof. Support beams 34 are preferably I-beams. Joists 32 and beams 34 are often fabricated from structural steel or wood. In FIGS. 1 and 2, joists 32 and beams 34 are depicted as relatively flat structures, but as shown in FIG. 3, the deflection detection system may also be used with crowned structures. FIG. 3 shows that joists 32 may be formed to provide a crowned contour.
A target block 22 is preferably positioned at the center of each joist 32, and extends downwardly below joist 32. For crowned joists, as shown in FIG. 3, a target block 22 is preferably located at the crown of each joist 32. Although target blocks 22 are preferably affixed to joists 32, depending on the construction of the building, target blocks 22 may instead be affixed to support beams 34. Because the structural framing of the building may affect the placement of target blocks 22, the structural frame may also determine the size and quantity of zones 26.
Target blocks 22 normally are positioned over beams 16 and each block occupies an open area between a joist 32 and a beam 16. The distance of target block 22 from beam 16 determines how much deflection in joist 32 must occur before alarm 18 is triggered by receiver 14. The amount of deflection necessary to trigger alarm 18 depends on the load requirements, the modulus of elasticity, and the flexibility of joists 32 and beams 34. These factors may be used to calculate the predetermined distance at which sources 12 and receiver 14 should be place beneath structure 30 and target blocks 22. An exemplary distance is about 1.5 inches for a 40 foot beam 34. Sufficient deflection in any one of joists 32 caused by, for example, a weight overload condition on the roof, will cause target block 22 to be displaced into the path of beam 16, so that an exterior edge of block 22 breaks the beam's contact with receiver 14. Alarm 18 will signal to a central monitoring station which receiver 14 sent the negative signal, and hence identify in which zone 26 the deflection occurred. Alarm 18 could further produce a visual readout of the structure and the deflection zones so that it can be determined which area of the building was being overstressed before it collapses.
Referring to FIGS. 4(a) and 4(b), in another embodiment of the present invention, in a first non-deflected state, a source of an energy beam (not shown) provides a beam spot 54 that hits target 50 but not receiver 52 (FIG. 4(a)). As in the previous embodiments, target 50 is preferably suspended from a roof structure 56. If roof structure 56 moves downwardly (FIG. 4(b)), target 50 also moves downwardly out of the beam path so that beam spot 54 hits receiver 52, thus causing the alarm to be triggered. Accordingly, as in the embodiments of FIGS. 1-2, the receiver has a first state in which it either receives or does not receive the energy beam, and has a second alarm state in which the receiver causes an alarm to be triggered. In the embodiment of FIG. 4, however, the states are reversed from those of the embodiment of FIGS. 1-2.
Referring to FIG. 5, an exemplary target 60 has an L-shaped body 62 with a vertical target plate 64 and a horizontal mounting plate 66. Mounting plate 66 has an opening through which a threaded rod 68 is disposed and fastened with two nuts 70, 72, one on either side of plate 66. At the top of rod 68 is a C-clamp 74 that is used to clamp the target overhead to the roof structure. The target here is generally shown as rectangular plate 64, but it may also have a cut-out portion, such as the recess shown by dashed line 76. In either of these embodiments, the target has an outer perimeter with an exterior edge 78 (which edge may include the edge portion defined by dashed line 76) that breaks the beam when it moves into the path.
Referring to FIG. 6, an exemplary bracket assembly 80 for connecting a receiver and/or a transmitter to a roof structure 82 is shown. The bracket is mounted to a pad 84 and includes a first bracket 85 with a horizontal portion 86 mounted to pad 84, a downwardly angularly extending portion 88, and an upwardly extending portion 90 that forms a V-shaped notch 89 with portion 88. A second bracket piece 92 is generally L-shaped with a vertical portion 94, a horizontal portion 96, and a small flange 98 extending downwardly from portion 96 (parallel to portion 94). Flange 98 extends into V-shape notch 89 formed between portions 88 and 90 of the first bracket. The vertical portion 94 has two openings for receiving threaded rods that extend through transmitter/receiver 100 for holding it to bracket 92. Where flange 98 seats in V-shape notch 89, the connection is not rigid, but rather is held through gravity. This type of connection allows transmitter/receiver 100 to hang vertically and to align itself.
Referring to FIG. 7, in a steel roof structure, an energy source 112 provides a beam 116 to a receiver 114 under a row of targets 118. Each of these targets may be of the type generally shown in FIG. 5, and the energy source and receiver are each preferably held with a bracket such as that shown in FIG. 6. In this steel roof, each section, known as a bay, has one energy source 112, one receiver 114, and a set of targets 118.
The system of the present invention can also sense not only downward deflection in a central portion of the roof, where it can be more susceptible to collapse due to excessive weight, but also kiting, a phenomenon that occurs when ends of a roof billow upwardly. In this case, when a receiver and/or a transmitter are connected to the ends of the roof structure, billowing of the roof ends will result in upward movement of the receiver and/or the transmitter relative to one or more targets, moving the light beam upwardly and causing the target(s) to break the energy beam.
Depending on its sensitivity, the system may also be able to sense deflections caused by individuals on the roof, including potential burglars.
It will be apparent to those skilled in the art that various modifications and variations are possible within the spirit and scope of the present invention. For example, various types of detectable energy beams, such as visible light, laser infrared, or microwave, may be used. A laser or infrared source can be pulsed at a rate that is sufficiently fast to prevent the receiver from sensing a break in the beam. The lasers could also be placed along the horizontal plane of a bridge to detect deflections in the road support structure. Rather than providing a plurality of separate energy sources corresponding to each zone, a single source may be used and split into multiple beams. In the case of a laser, the laser may be optically coupled to a plurality of fiber optic lines, each of which directs a beam to a corresponding receiver, thus avoiding the need for multiple lasers. | Deflections in supporting structures, due to external stress factors, can be detected with one or more energy beams generated along a path adjacent to the structure. Receivers are positioned in or near the path. Target blocks are positioned along the support structure. When a deflection occurs in the support structure, the targets are concurrently displaced into or out of the path. The receiver registers a change in state and activates an alarm. Multiple beams can be used to detect deflection in one of a number of predefined zones, the alarm indicating the zone in which the beam path was broken by the deflection. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to finishing or restoring the surface of a plastic article and more particularly to a method and apparatus for lowering the viscosity of the articles's surface, by exposing the surface to a solvent, thereby reforming the surface to a smooth finish.
In the past there has always been the problem of obtaining a smooth, high gloss finish to plastic products. Furthermore, since the advent of recycling, there is a demand for recycling or restoring plastic articles.
There have been several attempts to provide an apparatus for refinishing and reforming plastic articles. These attempts utilize various apparatus and solvents to refinish the plastic surface. One such attempt was to place an object made of plastic material into a zone of solvent vapors. The object was maintained in the zone for a sufficient amount of time for the solvent to be absorbed into the plastic's surface. The exposure of the surface to the vapor and the reaction thereto was controlled by changing the temperature of the object in relation to the zone. These past attempts did not adequately control the solvent vapor and further allowed the harmful solvent vapor to escape into the atmosphere.
Thus, there is a need to provide an apparatus and method of refinishing or finishing the surface of the plastic articles in which the solvent vapor is controlled, and which provides a high quality finish and does not release harmful gases into the atmosphere.
SUMMARY OF THE INVENTION
The present invention provides an apparatus and method, using a solvent for restoring or finishing the surface of a plastic article. The apparatus for restoring or finishing the surface of the plastic article controls the exposure of the surface to a finishing solvent. The apparatus has a finishing chamber for containing the solvent, controlling the solvent temperature, and exposing the surface to the solvent in a contact zone during a predetermined period of time.
A vaporizer in the finishing chamber vaporizes the solvent. The solvent vapor is conveyed to the contact zone. The finishing chamber has receiving and exiting ends for receiving the plastic article and removing the plastic article from the finishing chamber. The surface of the plastic article is exposed to the solvent vapor in the contact zone. Cooling coils, positioned at the top of the finishing chamber, cools the solvent vapor that rises above the contact zone. The cooling of the solvent vapors lowers the vapors back into the contact zone. The concentration of the solvent vapor in the contact zone is maintained by the cooling coils or vaporizer.
Attached to the receiving end of the finishing chamber is a receiving chamber for receiving and conveying the plastic through the contact zone of the finishing chamber. Attached to the exiting end of the finishing chamber is an exiting chamber for removing the plastic article from the finishing chamber once the surface of the plastic article is finished. A conveyor passes through the receiving, finishing and exiting chambers for conveying the plastic article therethrough. The receiving and exiting chambers capture any of the solvent vapor that escapes from the finishing chamber. The exiting chamber also captures the solvent vapor that evaporates off of the surface of the plastic article once the article is removed from the finishing chamber.
The invention also comprises a method of finishing the surface of the plastic article including the steps of vaporizing the solvent and conveying the solvent vapor into the finishing chamber. The concentration of solvent vapor is controlled in the finishing chamber by changing its temperature so that the solvent vapor is at predetermined concentration at the contacting zone in the finishing chamber. The plastic article to be treated is conveyed into the contacting zone in the finishing chamber and exposed to the solvent vapor for a predetermined amount of time so that the solvent is absorbed by the surface of the article. The absorbing of the solvent vapor lowers the viscosity of the surface and reforms the surface.
Once the predetermined time has expired the article is removed from the contact zone and the finishing chamber. When the plastic article is removed from the finishing chamber the solvent is allowed to evaporate off of the surface of the plastic article in the exiting chamber. After the solvent has evaporated the plastic article has a smooth finish for appropriate subsequent use thereof.
One object of the present invention is to provide an apparatus and method for restoring or finishing the surface of a plastic article to a smooth glass-like finish.
Another object of the present invention is to provide an apparatus and method which contains the solvent and prevents the releasing of the solvent into the atmosphere.
Other objects and advantages of the present invention will be apparent from the following description the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the apparatus for finishing plastics of the present invention; and
FIG. 2 is an elevational view of the apparatus for finishing plastics.
DESCRIPTION OF THE INVENTION
Initially, when a plastic article's surface is exposed to a solvent or solvent vapor, such as methanol, the solvent is absorbed into the surface of the article. The absorbed solvent lowers the viscosity of the first few molecular layers of the surface of the plastic. By lowering the viscosity, the surface of the plastic article will flow due to the surface tension of liquid. This flowing allows any blemishes or scratches in the surface to be eliminated thereby forming a smooth surface.
Preferably the surface will be exposed to a particular concentration of solvent vapor for a period of time such that the surface will flow to eliminate any defects on the surface and yet not flow excessively or become opaque due to over exposure to the solvent vapor.
Generally, referring to the drawings, the finishing apparatus of the present invention is designated as 10. A finishing chamber 12 is positioned between a receiving chamber 14 and an exiting chamber 16. The plastic article to be restored or finished will enter the finishing apparatus 10 on a conveyor 18 through receiving chamber 14. The conveyor 18 conveys the article into the finishing chamber 12 where it is exposed to the solvent for a predetermined amount of time. Once the predetermined time has expired the article will exit through exiting chamber 16.
The finishing apparatus 10 will remove scratches, mars or other imperfections from the surface of old plastic, such as Lexan, or will provide a finishing process for the manufacturing of new plastic articles, such as those made out of acrylic, resulting in a smooth glass-like finish. It should be noted that any type of plastic can be finished using the finishing apparatus of the present invention.
More specifically, referring to FIGS. 1 and 2, the finishing chamber 12 has three zones, defined by phantom lines 11, a heating zone 12a, a contact zone 12b and a cooling zone 12c. The heating zone 12a contains the liquid solvent to be used for restoring or finishing the article.
Preferably the solvent used in the finishing chamber 12 is methanol. It should be understood that any other solvent that lowers the viscosity of plastic can be used, such as, but not limited to, chloroform, acetone, methyl acetone, etc. and ether alcohol.
The solvent 20, located in the heating zone 12a is heated to a predetermined temperature, such as 150° F. This heating vaporizes the solvent 20. The heating of the solvent 20 may be provided by a heating coil 24. The heating coil 24 may be the high end of a cooling compressor 22, such as a R502 cooling unit manufacture by the Copeland Corporation, Model MSYOL-0035-IAA. The high end of the cooling compressor 22 will sufficiently heat the liquid solvent 20 until it evaporates.
It should be understood that any type of heating device may be used to heat the liquid solvent 20 in the heating zone 12a, but it is preferred that the high end of the cooling compressor be used due to its efficiency. Such heating devices can include, but not limited to, electric heating coils, oil heating coils or simply a gas burner placed underneath the heating zone 12a of the finishing chamber 12.
The solvent vapor 20b, having a temperature of approximately 140° F., will rise from the heating zone 12a into the contact zone 12b where it will contact the surface of the article entering into the finishing chamber 12 through receiving end 12r. The solvent vapor 20b will rise above the contact zone 12b into the cooling zone 12c of the finishing chamber 12.
Cooling or evaporator coils 30 of the cooling unit are positioned in the cooling zone 12c to cool the solvent vapor 20b that has raised above the contact zone 12b. Based on the principle that hot vapor rises and cool vapor descends, the cooling coils cool the solvent vapor 20b and lowers the solvent vapor out of the cooling zone 12c back into the contact zone 12b. Thus, by heating and cooling the solvent vapor the concentration of the solvent vapor in the contact zone 12b can be regulated and contained.
It should be noted that there is a direct relationship between the temperature of the solvent vapor and the concentration of the solvent vapor in the contacting zone. Thus, if the solvent vapor, such as methanol, is maintained at a predetermined temperature, such as to 110° F., the concentration of the solvent vapor will be sufficient for lowering the viscosity of the surface for reforming the surface of the article.
As part of the cooling process the cooling coils 30 capture a portion of the solvent vapor by condensing the solvent vapor back into a liquid. The condensed solvent flows downs the walls 32 of the finishing chamber 12, returns back to the heating zone 12a and is reheated and vaporized. The process of heating, cooling and condensing the solvent is continuous throughout the finishing of the article such that the proper conditions are provided for finishing the article in the contacting zone 12b.
The temperature of the solvent 20 and the solvent vapor is controlled and regulated by temperature indicators and controls. Temperature indicator 26 is positioned in the heating zone 12a to continually monitor the temperature of the solvent. Temperature indicator 27 located in the cooling zone, continually monitors the temperature of the solvent vapors in the cooling zone 12c.
The temperature indicators 26 and 27 are preferably Johnson Controls temperature indicators Model Number D350AA-1 which outputs a temperature ranging from -30° F. to 250° F. The signal from the temperature indicator 26 is used to regulate and control the heating of the liquid solvent 20 by the heating coils 24 and the cooling of the solvent vapor 20b by cooling coils 30 in the cooling zone 12c.
A temperature control 28, such as a Penn Control Model Number A350AA-1 is used to regulate the temperature of the heating coils 24 and the cooling coils 30 based upon the readings from the temperature indicators 26 and 27. The temperature control 28 may be regulated to decrease or increase the temperature of the cooling coils 30 in order to maintain the temperature in the cooling zone within the desired range for finishing the article's surface.
For example, if plastic is being finished through the finishing chamber 12 by using methanol, then the temperature of the solvent vapor in the contact zone 12b should be controlled at a temperature range between 20° F. and 140° F. The temperature of the heating coils 24 and cooling coils 30 can be microprocessor controlled.
In order to facilitate the finishing process, receiving 14 and exiting chamber 16 are used to continually convey the article to be finished, or restored, into and out of the finishing chamber 12. The receiving chamber 14 is attached to the finishing chamber's receiving end 12r with the conveyor 18 running therethrough for carrying the article into the contacting zone 12b of the finishing chamber 12. The top portion 14a of the receiving chamber 14 captures any of the solvent vapor 20c that escapes from the finishing chamber 12.
Located at the top of the receiving chamber are cooling coils 36 for condensing the escaped solvent vapor 20c into a liquid. These cooling coils 36 are connected to the cooling unit 18 compressor 22. The condensed liquid solvent runs down side walls 14b to the bottom 14c of the receiving chamber 14. The bottom wall 14c is sloped down towards the heating zone 12a of the finishing chamber 12 and directing the condensed solvent back into the finishing chamber 12 to the heating zone 12a.
A temperature indicator 42, such as the Johnson Controls Model D350AA-1, and a temperature control 44, such as the Penn Control Model A350AA-1, monitors the temperature of the receiving chamber. The temperature in the receiving chamber 14 is controlled through solenoid valve 50 such as Sporlan Controls Model A3F1, and a back pressure regulator 54 constant pressure such as a Sporlan Controls Model ORIT 658050. The valve 50 and the regulator 54 regulates the temperature to insure the proper capturing and condensing of the escaped solvent vapor 20c from the finishing chamber 12.
Similar to the receiving chamber 14, the exiting chamber 16 is attached to the finishing chamber 12 for conveying the finished article out of the finishing chamber 12 through exit 12e. The conveyor 18 extends through exit 12e and the exiting chamber 16 to convey the article out of the finishing chamber 12. The top portion 16a of the exiting chamber 16 captures any solvent vapor 20d that escapes from the finishing apparatus 10. Furthermore, the exiting chamber 16 captures the solvent 20e that evaporates off of the article exiting the contacting zone 12b.
Located at the top 16a of the exiting chamber 16 are cooling coils 40 for condensing the escaped 20c or evaporated 20e solvent vapor. The cooling coils 40 are connected to the compressor 22 of the cooling unit. As in the receiving chamber 14 the condensed liquid solvent runs down side wall 16b into bottom wall 16c of the exiting chamber 16. The condensed liquid solvent is directed back into the finishing chamber's heating zone 12a for vaporization by the sloped bottom wall 16c.
As in the receiving chamber 14, a temperature indicator 46, such as the Johnson Controls Model D350AA1, monitors the temperature of the exiting chamber 16. A solenoid valve 50, such as a Sporlan Controls Model A3F1, and a back pressure regulator 54, such as a Sporlan Control Model ORIT 658050, controls the cooling of coils 40 to insure the proper capturing and condensing of the escaped and evaporated solvent vapor from the finishing chamber 12. The temperature control 44 controls both the receiving 14 and exiting chambers 16 temperature.
As stated above, the temperature indicator and temperature controls of the receiving 4 and exiting 16 chambers can be linked to a microprocessor in order to maintain the appropriate level of solvent vapors in the contacting zone 12b.
While the method herein described, and the form of apparatus for carrying this method into effect, constitute preferred embodiments of this invention, it is to be understood that the invention is not limited to this precise method and form of apparatus, and that changes may be made in either without departing from the scope of the invention, which is defined in the appended claims. | An apparatus for finishing or restoring the surface of a plastic article. A receiving chamber receives the article and conveys the article to a finishing chamber. The surface of the article is exposed to a control led concentration of solvent vapor for a period of time in the finishing chamber. The solvent vapor is absorbed into the surface of the article and reforms the surface of the article to a smooth finish. The solvent evaporates off of the surface of the article leaving a smooth glass like finish. A refrigeration system condenser and evaporator are provided to respectively vaporize the solvent in a heating zone, and condense the vaporized solvent in a cooling zone. | 1 |
This application is the U.S. national phase of International Application No. PCT/IB2011/055385, filed 30 Nov. 2011, which designated the U.S. and claims priority to IT Application No. RM2010A000622, filed 30 Nov. 2010; the entire contents of each of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a novel process for the synthesis of Nebivolol.
Nebivolol is a racemic mixture of the two enantiomers [2S[2R[R[R]]]] α,α′-[imino-bis(methylene)]bis[6-fluoro-chroman-2-methanol] and [2R[2S[S[S]]]] α,α′-[imino-bis(methylene)] bis[6-fluoro-chroman-2-methanol] (FIG. 1).
In particular, it is reported the enzymatic resolution of the starting chromanyl ester (1) by treatment with a stereoselective enzyme belonging to the family of esterases, in a native or recombinant form, obtainable also from the microorganism Ophiostoma novo - ulmi.
The esters and acids thus obtained can be converted, by processes known to a person skilled in the art, into the corresponding “semichiral” epoxides, i.e. the pairs (RR+RS, 4) and (SS+SR, 5) of Scheme (1).
In turn, the components of each pair can be separated by exploiting their different reactivity with benzylamine in a solvent consisting of a tertiary alcohol. Under these conditions of kinetic resolution, the epoxides RS and SR will be converted into the corresponding opening products (6 and 8), whereas the epoxides RR and SS will remain unaltered.
The epoxide RR (7) is then separated from amine RS (6) and the epoxide SS (9) is separated from amine SR (8) with processes known to a person skilled in the art and preferentially by crystallization of the basic component.
Then, the amine RS is reacted with the epoxide SS to obtain l-benzylnebivolol. Likewise, the amine SR is reacted with the epoxide RR to obtain d-benzylnebivolol.
The l- and d-benzyl Nebivolol thus obtained are pooled in equimolar amounts, crystallized and converted into Nebivolol HCl according to processes known to a person skilled in the art.
STATE OF THE ART
Nebivolol is known as an adrenergic beta-receptor antagonist, an antihypertensive agent, a platelet aggregation inhibitor and a vasodilating agent.
Nebivolol has basic properties and may be converted into an acceptable pharmaceutical salt form by treatment with an acid. The hydrochloride salt is the marketed form.
Nebivolol contains four asymmetric centres, and therefore 16 stereoisomers are theoretically possible. However, because of the particular structure of the molecule (the presence of an axis of symmetry), only 10 stereoisomers can actually be formed (Scheme 2).
SCHEME 2
Possible stereoisomers for Nebivolol
B =
A =
SSSS
SSSR l-nebivololo
SSRR
SSRS
RSSS (= SSSR)
RSSR
RSRR
RSRS
RRSS
RRSR
RRRR
RRRS d-nebivololo
SRSS
SRSR
SRRR (= RRRS)
SRRS
In fact, because of the symmetry of the molecule, RSSS=SSSR, RRSS=SSRR, SRSS=SSRS, RRSR=RSRR, SRSR=RSRS and RRRS=SRRR.
U.S. Pat. No. 4,654,362 (EP 0145067, Janssen) describes the synthesis of products of Nebivolol series with use of epoxide isomers as key intermediates in the synthesis. The products are obtained sometimes in mixture and sometimes enantiopures, without defining the absolute configuration. In particular, example 84 of said patent describes the obtainment of a mixture of isomers as defined in Scheme 3.
These are separated, with a chromatography column, into the two epoxide racemates (RS/SR, 4/5) and (RR/SS, 7/9). There follow the opening of a pair of epoxides (4+5) with benzylamine and the use of the products of said reaction (6+8) to open the second pair of epoxides (7+9). This operation leads to the production of the 4 benzylated diastereoisomers (10-14).
EP 0334429 (Janssen) describes the same process reported in EP 0145067, but with more experimental details and with attention focused on the preparation of a single isomer of Nebivolol. In this case, specifically 6-fluorochroman carboxylic acid is resolved into the individual enantiomers by treatment with (+)-dehydroabiethylamine. The individual enantiomers thus obtained are converted into the corresponding semichiral epoxides according to the following synthetic scheme (isomer S shown):
A stereoselective synthesis of isomer [2R,αS,2′S, α′S]-α,α′-[iminobismethylene]bis[6-fluoro-3,4-dihydro-2H-1-benzopyran-2-methanol] is described.
The process for the resolution of acid esters used suffers from several drawbacks for what concerns its industrial application. In fact, additional steps (amide forming, fractionated crystallization, amide hydrolysis) are introduced, and moreover the overall yield is rather low. The mixture of diastereoisomeric epoxides thus obtained is run on preparative HPLC to isolate the isomer of desired chirality.
Hetero Drugs Limited, in WO 2006/016376 and in the subsequent WO 2007/083318, describes fractionated crystallization processes applied at the level of the diastereoisomeric mixture (10, 11, 13, 14) of benzyl Nebivolol, which lead, in this case as well, to a discarding of about 50% of the starting material, related to the need to remove unwanted diastereoisomers.
WO 2007/041805 (Egis Gyógyszergyár) describes a process for the preparation of [2S*[R*[R*[R*]]]] and [2R*[S*[S*[S*]]]]-(±)-α,α′-[iminobis(methylene)]bis[6-fluoro-3,4-dihydro-2H-1-benzopyran-2-methanol] and its individual pure [2S*[R*[R*[R*]]]] and [2R*[S*[S*[S*]]]] enantiomers starting from very different compounds. The steps used for Nebivolol synthesis as mixture of enantiomers are about thirty, making the synthesis very lengthy and uneconomic (Scheme 5).
In WO 2008/010022 (Cimex Pharma) a route is reported that, starting from 6-fluoro chroman carboxylic acids resolved according to processes in the literature, leads to the synthesis of the two Nebivolol enantiomers according to two separate sequences (Scheme 6, for d-Nebivolol).
In the opening of epoxides by a benzylamine, a single opening product crystallizes from the reaction mixture, but the other diastereoisomer is removed with the mother liquors, leading in this case as well to the elimination of a considerable fraction of material in an already quite advanced stage of the synthetic sequence. In addition, the last chiral centre is added at the penultimate step by reduction of a ketone, quite a sensitive reaction, which in order to obtain optimal results envisages the use of KBH 4 and titanium isopropoxide.
WO2008/064826 (Zach System) reports a process for the resolution of epoxides, once the pairs of diastereoisomers (RS/SR and RR/SS) have been separated chromatographically, through the enantioselective opening of the same epoxides mediated by chiral complexes of cobalt II (Scheme 7). In this case a chromatographic separation step is necessary, less than practical from the standpoint of the process, while cobalt complexes require caution in manipulation and disposal.
WO 2008/064827 (Zach System) describes the separate and enantioselective synthesis of d- and l-Nebivolol starting from the two optical isomers of the protected glyceraldehyde, such as 2,2-dimethyl acetale (Scheme 7). The diastereoisomers are separated with processes known, but not described. The number of synthetic steps is higher than that of classic synthesis, while aldehyde precursors are known as compounds not overly stable, which tend to polymerize when stored in a pure form and at room temperature.
As to enantiomer separation at the level of the 6-fluoro-chroman-2-carboxylic acid, it is known that the process for amide formation with (+)-dehydroabiethylamine, followed by fractional crystallization and amide hydrolysis to recover the acid (EP 0334429), is toilsome and affords rather low yields.
Concerning the enzymatic resolution of esters of carboxylic acids, this is a process known in the literature, but it had never been employed on esters of fluorine derivatives of chroman-2-carboxylic acids, nor consequently used for Nebivolol synthesis.
Specifically, known examples related to chroman-2-carboxylates are reported.
In U.S. Pat. No. 5,037,747, (2R)-hydroxy-substituted benzopyran-2-carboxylic esters and (2S)-hydroxy-substituted benzopyran-2-carboxylic acids are prepared by the Pseudomonas lipase-catalyzed selective hydrolysis of the corresponding racemate.
Urban (U.S. Pat. No. 5,089,637, EP 0448254) exploits an enzymatic hydrolysis with an esterase derived from Pseudomonas fluorescens to resolve racemic mixtures of general formula (I), where R═C 1 -C 3 alkyl.
WO 96/40975 reports the use of a microbial esterase derived from Serratia marcescens for the resolution of chroman-2-carboxyl alkyls of the same general formula, but with R>C 3 .
In DE 4430089 it is reported a series of examples in which chroman-2-carboxyl esters are subjected to enzymatic hydrolysis with a selected group of enzymes (chymotrypsin, lipase from Candida lipolytica , lipase from Aspergillus oryzae , lipase from Geotrichum candidum , lipase from Aspergillus niger ).
Finally, as to the esterase derived from Ophiostoma novo - ulmi ascomycete, the details related to its isolation, cloning in E. Coli and to its use in the resolution of esters are reported, e.g., by M. N. Isupov et al. in Acta Crystallographica—Biological Crystallography Section D60, p. 1879-1882 (2004), or in EP 0687305, while an use thereof in the resolution of enantiomers of arylalkanoid acids and, more specifically, of ketoprofen, is described in EP 0693134.
On the basis of literature evidence available to date, Nebivolol synthesis still entails numerous synthetic problems. The original Janssen synthesis going through the epoxides (Scheme 3, mixture 6) is surely the shorter one, but requires a separation by preparative HPLC of the two diastereoisomeric epoxide pairs. The other processes generally envisage many more synthetic steps.
In a sizeable part of the synthesis reported, intermediate product percentages, which may arrive up to the 50%, are discarded to eliminate unwanted diastereoisomers that have unavoidably been produced in the synthetic sequence applied.
Therefore, the need to develop a novel synthetic process, suitable for industrial use and avoiding the use of chromatographic separations and the need to eliminate sizeable percentages of intermediate compounds though maintaining a limited number of synthetic steps, is markedly felt.
SUMMARY OF THE INVENTION
It has now surprisingly been found a more effective process for the synthesis of Nebivolol (Scheme 1) which allows to eliminate the drawbacks highlighted hereto for the synthesis routes previously known, i.e., it:
a) avoids, or considerably reduces, separation by preparative HPLC of the pairs (RR/SS RS/SR) of epoxides enantiomers or of other diastereoisomeric intermediates;
b) sensibly reduces the loss of product represented by undesired isomers, with a consequent increase of the overall yield.
The treatment of the mixture of the two enantiomers of the 6-fluorochroman-2-carboxylic acid ester is performed with a fungal esterase (lipase) obtainable from genus Ophiostoma . The preferred species is esterase from Ophiostoma novo - ulmi , already described in the literature for its stereoselective activity on the esters of naproxen or ketoprofen compounds.
The reaction carried out in an aqueous or aqueous/organic medium leads to hydrolysis to carboxylic acid of one of the two enantiomers in a selective manner, while the other one remains in the form of an ester. The reaction proceeds quickly and with a high stereoselectivity. The two compounds thus produced can be easily separated by acid-base extraction.
Therefore, object of the present invention is a process for the preparation of Nebivolol, the process comprising:
a. resolving, by an enzymatic hydrolysis reaction, the mixture of enantiomers of a 6-fluoro-2-carboxylic acid ester (1), wherein R 1 is a linear or branched C 1-5 alkyl group,
to give a mixture of acid (2) and ester (3)
wherein the R acid (2) is present with an enantiomeric excess of >70% and the S ester (3) is present with an enantiomeric excess of >70%; the enantiomeric excess is preferably of >80%, and even more preferably of >90%, in both components;
b. using thus obtained acid (2) and ester (3) for the synthesis of the mixtures of epoxides (4) and (5),
c.1) The kinetic resolution reaction with benzylamine on the mixtures of epoxides (4) and (5) in a sterically hindered alcohol to obtain respectively the compounds (6)+(7) and (8)+(9) and their separation
c.2) Alternatively to the kinetic resolution described at c.1), chromatographic separation of the mixtures of epoxides (4) and (5) and subsequent reaction of the RS epoxide with benzylamine to give the amino alcohol RS (6) and the epoxide SR with benzylamine to give the amino alcohol SR (8).
d. reacting the amino alcohol RS (6) with the epoxide (9) to obtain l-benzyl Nebivolol (10) and the amino alcohol SR (8) with the epoxide (7) to obtain d-benzyl Nebivolol (11)
e. deprotecting, with removal of the benzyl group with Nebivolol formation
To the ends of the present invention the group R 1 , defined as a linear or branched C 1-5 alkyl group, represents a radical selected from: methyl, ethyl, propyl, isopropyl, butyl, sec-butyl, tert-butyl, amyl, tert-amyl; preferably it is a radical selected from methyl, ethyl, propyl, and even more preferably it is an ethyl group.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, the Nebivolol compound is obtained with the process described in Scheme 1 starting from the racemic mixture of the 6-fluorochroman-2-carboxylic acid ester (1).
6-fluorochroman-2-carboxylate (1) may be resolved into its two enantiomers with high stereoselectivity through enantioselective hydrolysis catalyzed by a fungal esterase (lipase) obtainable from genus Ophiostoma . The preferred species is esterase from Ophiostoma novo - ulmi , already described in the literature for its stereoselective activity on the esters of naproxen or ketoprofen compounds.
The enzyme, in the form of an isolated and crystallized expression protein, is described by M. N. Isupov et al. in Acta Crystallographica—Biological Crystallography Section D60, p. 1879-1882 (2004). The enzyme is also described in EP-B1-0687305 (WO94/20634), EP-0693134, U.S. Pat. No. 5,912,164, and in EP1626093.
Enzyme expression in E. coli may be performed as described by M. N. Isupov et al. (supra) or in EP-B1-0687305 (WO94/20634).
This strain provides a good example of activity, however, given the rather diffused nature of activity in a wide variety of related strains, the scope of the invention is not meant to be limited only thereto. The microorganisms of genus Ophistoma and their enzymatic activity may be used to hydrolyze the racemic ester of 6-fluorochroman-2-carboxylated ethyl in a stereoselective manner, so as to bring to the acid, considerably enriched in enantiomer R., e.g. 93-100% of enantiomeric eccess with a 45-50% of conversion, and leave the enriched residual ester in the enantiomer S.
It is therefore produced the (R) 6-fluorochroman-2-carboxylic acid (2) with an enantiomeric excess of >70%, preferably of >80% and even more preferably of >90%, while the (S) 6-fluoro carboxylic acid remains in the form of an ester (3) with an enantiomeric excess of >70%, preferably of >80% and even more preferably of >90%.
The reaction may be conducted on any mixture of enantiomers, but generally the racemate is used.
The ester used for this reaction is a 6-fluoro-2-carboxylic acid ester (1), wherein R 1 is a linear or branched C 1-5 alkyl group, selected from the group comprised of methyl, ethyl, propyl, isopropyl, butyl, sec-butyl, tert-butyl, amyl, tert-amyl; preferably from methyl, ethyl, propyl and even more preferably from an ethyl group.
The reaction is preferably conducted at a pH 8-11, preferably 8.5-10.0.
The temperature may be comprised between 10 and 35° C., but preferably between 20 and 25° C.
The reaction mixture may be in an aqueous environment, or in the presence of water-immiscible solvents.
Recovery of both compounds is possible by processes known to a person skilled in the art and preferably through a series of acid-base extractions.
Both compounds are then used for Nebivolol synthesis (Scheme 1).
Through processes known to a person skilled in the art (by way of a non-limiting example, analogously to that described in WO2007041805) the acid (2) is transformed into the mixture of epoxides (RS) and (RR) (4), diastereoisomeric therebetween, while the ester (3) is converted into the mixture of epoxides (SR)+(SS)
(5).
By performing the reaction of opening of the mixture of epoxides (4) with benzylamine in a sterically hindered alcoholic solvent (such as isopropanol, sec-Butanol, tert-butanol, 2-methyl-2-butanol, isoamyl alcohol, 2-methyl-2-pentanol) it is had a kinetic resolution with formation of the sole amino alcohol RS (6), while the epoxide RR (7) is recovered as unchanged.
The same procedure, applied to mixture (5), produces amino alcohol SR (8) and epoxide SS (9).
Alternatively to the kinetic resolution described, the mixture of epoxides (4) may be chromatographically separated into the two epoxides RS and RR, and the mixture of the epoxides (5) into the two epoxides SR and SS; subsequently the epoxide RS is reacted with benzylamine obtaining the amino alcohol RS (6), while the epoxide SR is reacted with benzylamine to obtain the amino alcohol SR (8).
Finally, the reaction of the amino alcohol (6) with
the epoxide (7) produces the N-benzylated derivative of l-Nebivolol (10), and analogously the reaction of the amino alcohol (8) with the epoxide (9) provides the N-benzylated derivative of d-Nebivolol (11).
The compounds (10) and (11) are pooled in equimolecular amounts, purified by crystallization (so as to eliminate any impurities constituted by unwanted diastereoisomeric compounds deriving from non-complete enantiomeric purity of the starting esters/acids), debenzylated and subsequently salified to obtain the desired final Nebivolol salt.
EXAMPLES
The invention is hereinafter described in detail by the following examples, purely by way of illustration and not for limitative purposes:
Example 1
As described in EP-0687305, a strain of recombinant E. Coli containing the esterase originally expressed in Ophiostoma novo - ulmi is cultivated according to techniques well-known to a person skilled in the art. A cell fraction is lysed by sonication and the lysate centrifuged to obtain a cell-free supernatant solution. 1.6 mL of solution containing the esterase (lipase) enzyme obtained from Ophiostoma novo - ulmi (6800 units/mL) and a suspension of about 25 g of ethyl 6-fluorochroman-2-carboxylic acid (1) in 25 mL of deionized water with 100 μL of Tween 80, are added to 500 mL of a 0.1N NaHCO 3 buffer solution (pH 9.7), optionally adjusting the pH with 2N NaOH to a value of 9.7. The mixture thus obtained is gently stirred.
pH is automatically maintained at the value of 9.7 with controlled additions of a 2N NaOH solution.
Evolution of the reaction is controlled by HPLC.
At the end of the hydrolysis reaction, the mixture is extracted with dichloromethane so as to obtain the ester in the organic phase. The aqueous solution is acidified with 1N hydrochloric acid to pH 1, and then extracted with dichloromethane for recovery of the acid.
The two organic phases are separately washed with brine, and concentrated to obtain respectively 12.2 g of ethyl ester and 11.0 g of acid.
Enantiomers ratio (HPLC):
(S) ester (3)/(R) ester: 95.31/4.69
(R) acid (2)/(S) acid: 95.36/4.64
Evaluation of rotatory power in DMF at 25° C. for the mixture of acids (comprising the acid (2)) shows said mixture to be levorotatory and in accordance with what reported in EP0334429 for the R isomer.
ACID (2) 1H-NMR (DMSO-D6, 400 MHz): δ H . (ppm): 2.04 (2H, m, OCHCH 2 CH 2 ), 2.64 (1H, m, OCHCH 2 CH 2 ), 2.79 (1H, m, OCHCH 2 CH 2 ), 4.75 (1H, t, J=4.5 Hz, OCHCO), 6.80-7.00 (3H, m, CHar), 13.00 (1H, b, COOH).
ETHYL ESTER (3) 1H-NMR (DMSO-D6, 400 MHz): δ H . (ppm): 1.19 (3H, t, J=7.2 Hz, CH 3 ), 2.04 (1H, m, OCHCH 2 CH 2 ), 2.14 (1H, m, OCHCH 2 CH 2 ), 2.62 (1H, m, OCHCH 2 CH 2 ), 2.80 (1H, m, OCHCH 2 CH 2 ), 4.86 (1H, t, J=4.5 Hz, OCHCO), 6.80-7.00 (3H, m, CHar)
Analysis process: Kromasil 5-AmyCoat (4.6×250 mm) column; eluents: (A) hexane (0.1% TFA), (B) isopropanol, isocratic (A)/(B) 85/15; flow: 1 mL/min, temperature: 40° C.; Detector: UV at 280 nm;
Example 2
Preparation of Acyl Meldrum Derivative
28 g of resolved (R) acid are solubilized in 250 mL anhydrous dichloromethane; to the resulting solution, 1.4 equivalents of oxalyl chloride and DMF dropwise are added. The solution is maintained under stirring at room temperature and under N 2 ; after 1.5 hours solvent is evaporated, obtaining an oil that is redissolved into 200 mL anhydrous dichloromethane. Separately, Meldrum's acid (1.05 equivalents) and pyridine (2 equivalents) are dissolved in anhydrous dichloromethane (150 mL) and left under stirring at 0° C. for 15 min. To this solution the previously formed acid chloride is added. At the end of the adding the mixture is left under stirring at 0° C. for 1 hour, and other 45 min at room temperature. Then, it is diluted with other 500 mL dichloromethane and the organic phase is washed with H 2 O (2×200 mL), 2N HCl (100 mL), water, and brine, and dried on Na 2 SO 4 . An oil is obtained which is taken up with 20 volumes of diisopropyleter, obtaining a brown solid (40 g, HPLC purity=81%, λ=280 nm) which is filtered and dried. The obtained solid is used in the subsequent reaction without further purification.
Example 3
Preparation of β-Keto Ester
40 grams of crude acyl Meldrum derivative (R) are placed under stirring with 110 mL tert-butanol; the resulting mixture is heated to 80° C. for 1 h until a control by HPLC highlights the disappearance of the starting product. At the end of the reaction, tert-butanol is evaporated under reduced pressure; it is taken up with 500 mL ethyl acetate and the organic phase is washed with a saturated NaHCO 3 solution, H 2 O to neutrality, brine and it is dried on Na 2 SO 4 . Then the solvent is evaporated, obtaining 28 g of crude β-keto ester (HPLC purity=69%, λ=280 nm) as an oil, which is used in the subsequent reaction without further purification.
Example 4
Preparation of Chloro β-Keto Ester
28 g of crude β-keto ester (R) are dissolved in 250 mL ethyl acetate, and to this solution 0.26 equivalents of Mg(ClO 9 ) 2 are added. After 30 min, 0.95 equivalents of N-chlorosuccinimide are added in 2 h. At the end of the addition, the resulting mixture is stirred for 1 hour at room temperature. Then the solid formed is eliminated, the clear solution is transferred into a separating funnel, after diluting with other 350 mL of ethyl acetate; the organic phase is washed with brine, H 2 O, and dried on Na 2 SO 4 . The solvent is evaporated, obtaining 34 g of crude chlorine derivative (HPLC purity=79.40%, λ=280 nm) which is used in the subsequent reaction without further purification.
Example 5
Preparation of α-Clorochetone
34 g of crude chloro β-keto ester (R) are refluxed with HCOOH (100 mL), CH 3 COOH (120 mL) and H 2 O (30 mL); after 1.5 h a control by HPLC highlights the end of the reaction. The mixture is then evaporated under reduced pressure, taken up with ethyl acetate, and the organic phase is washed with brine, saturated NaHCO 3 , H 2 O, and dried on Na 2 SO 4 . Then, the solvent is evaporated under reduced pressure, obtaining 21 g of α-chloro-ketone (HPLC purity=60%, λ=280 nm) as an oil that is used tel quel for the next step without further purification.
Example 6
Preparation of α-Chloroalcohol
21 g of the oil obtained from the preceding reaction are dissolved in 15 volumes of MeOH, to this solution 2.0 equivalents of NaBH(OCOCH 3 ) 3 are added with a spatula, and it is kept under magnetic stirring at room temperature. After 45 min another equivalent of NaBH(OCOCH 3 ) 3 is added. After 1 hour from the last addition, a control by HPLC denotes the end of the reaction. The solvent is evaporated under reduced pressure, all is transferred into a separating funnel with ethyl acetate and the organic phase is washed with H 2 O and brine, and dried on Na 2 SO 4 . There are obtained 21 g of an oil that is purified by flash chromatography (silica/crude ratio: 30:1, eluent: petroleum ether/AcOEt 92:8), obtaining 14.2 g of a chloro-alcohol (HPLC purity=86.5%, λ=280 nm).
Example 7
Preparation of (RR+RS) Epoxides (4)
14 g of α-chloro-alcohol are dissolved in 20 volumes of anhydrous Et 2 O, and to this solution 2.8 g of preceding NaH, washed with petroleum ether, are added. After 1 hour a control by TLC (silica gel, eluent: petroleum ether/AcOEt 85:15) denotes the disappearance of the starting chloro alcohol (one blot in TLC) and the formation of the two epoxides (two clearly distinct blots on TLC). The reaction mixture is then diluted with other 30 volumes of Et 2 O, and all is poured in 100 mL of 1M NaHSO 4 , maintaining a brisk stirring. The organic phase is washed with NaHCO 3 , H 2 O, brine, and dried on Na 2 SO 4 . The solvent is then evaporated under reduced pressure, obtaining 11.4 g of the mixture of epoxides as an oil (HPLC Purity>98%, λ=280 nm) in a ratio of 51:48.
The presence of only two main peaks in the ratios indicated in the analysis with chiral HPLC shows that no racemization was had in the reaction sequence going from the (R) acid to the mixture of diastereoisomeric (RR+RS) epoxides, with evident preservation of stereocenter chirality.
The mixture of (SR+SS) epoxides (5) is prepared analogously to what described in examples 2-7, starting from the ester (3) after its hydrolysis to the corresponding acid. In this case, the evaluation of the rotatory power in DMF at 25° C. for the acid thus obtained shows it as dextrorotatory and in accordance to what reported in EP 0334 429A1 for isomer S.
Example 8
Kinetic Resolution on the Mixture of (SS+SR) Epoxides
A solution of the mixture of (SS+SR) epoxides (4.50 g, 22.5 mmol) and benzylamine (3.8 mL, 35 mmol) in 2-methyl-2-butanol (38 mL) is mixed at room temperature for 12 hours. At the end of the reaction, formed (SR) amine 8 is filtered under vacuum and dried (1.90 g, 6.30 mmol). The filtered solution is poured in cyclohexane (250 mL) and the solution thus obtained is washed with 1M NaHSO 4 (100 mL) and H 2 O (50 mL×2), and then concentrated under reduced pressure to obtain 1.30 (6.00 mmol) g of (SS) epoxide 9.
Kinetic resolution on the mixture of (RS+RR) epoxides is conducted analogously to what described in Example 8.
Example 9
Synthesis of l-Benzyl Nebivolol (SSSR)
The compound (RS)-2-benzylamino-1-(6-fluorochroman-2-yl)ethanol and the (SS) epoxide are dissolved in absolute ethanol (6 mL) and maintained at reflux until disappearance of the starting reagents. At the end of the reaction the mixture is left to reach room temperature and the solvent is removed under reduced pressure.
Example 10
Synthesis of d-Benzyl Nebivolol (RRRS)
The compound (SR)-2-benzylamino-1-(6-fluorochroman-2-yl)ethanol and the (RR) epoxide are treated as in Example 9 to obtain d-benzyl Nebivolol.
Example 11
Synthesis of d,l-Benzyl Nebivolol
The 1-benzyl Nebivolol described in Example 9 (3.00 g) and the d-benzyl Nebivolol described in Example 10 (3.00 g) are pooled and the mixture thus obtained (6.0 g) is purified by crystallization, obtaining 5.0 g of N-benzyl Nebivolol (83%, HPLC purity=99.6%). During purification by crystallization there are eliminated also the impurities consisting of undesired isomers deriving from non-complete enantioselective hydrolysis of the starting ethyl 6-fluorochroman-2-carboxylic acid (1).
Example 12
Synthesis of Nebivolol Hydrochloride
The compound d,l-benzyl Nebivolol (5.0 g, 410 mmol) is dissolved in methanol (400 mL) together with 20% Pd(OH) 2 /C (1% b/w). The mixture is maintained under stirring and under hydrogen atmosphere. At the end of the reaction the catalyst is filtered on a porous septum, and concentrated HCl (36 mL) is added to the filtrate. The solution is concentrated under reduced pressure and the residue obtained is heat-treated with absolute ethanol (50 mL). The obtained solid is filtered and dried under vacuum (1.0 g, yield: 82%, HPLC purity: 99.9%)
HPLC Analytical Method
Column
Merck LiChrosphere 100 RP 18 endcapped
(5 μm) (4.6 × 250 mm)
Eluent
A: water + 0.1% TFA, B: acetonitrile +
0.1% TFA
Gradient: from 40% B to 90% B in 20 min +
isocratic 90% B in 10 min
Injection
20 μL
volume
Flow
1 mL/min
Detector
LC: UV. λ: 280 nm
Temperature
Room temperature | The present invention relates to a novel process for the synthesis of the Nebivolol product depicted in Scheme 1, comprised of a reduced number of high-yield steps, and characterized by the enzymatic resolution of the chroman ester precursor. | 2 |
TECHNICAL FIELD
The present invention relates to a powerless automatic tee up machine, and more particularly, to a powerless automatic tee up machine which repeats the transporting of golf balls onto a golf tee through potential energy, a cam curve, and a link system without using power, and which has a maximally simplified transporting structure to significantly reduce manufacturing costs.
BACKGROUND ART
In general, tee up machines automatically place golf balls on a tee to allow users to repeatedly practice a golf swing. Most conventional tee up machines that use a sensing device such as a sensor with power suffer from space restrictions due to use of power. They may also have high manufacturing cost and maintenance problems in case the sensor fails.
To solve these problems, an example of a conventional powerless tee up machine has been designed to carry a golf ball to a tee through an arm which rotates due to the weight of the golf ball. The conventional tee up machine has to manually position a golf ball on an arm using a pedal or has a complicated structure for controlling the direction in which the arm rotates, thereby resulting in high manufacturing cost. The conventional tee up machine may also generate noise due to rotation of the arm or have difficulties in correctly putting a golf ball on a golf tee.
DETAILED DESCRIPTION OF THE INVENTION
Technical Problem
The present invention provides a powerless automatic tee up machine for repeatedly teeing up golf balls through a simple structure, thereby having low maintenance and manufacturing costs.
The present invention also provides a powerless automatic tee up machine designed to absorb kinetic energy produced while teeing up a ball or use the kinetic energy for sequential arrangement of golf balls.
Technical Solution
According to an aspect of the present invention, there is provided a powerless automatic tee up machine including: a main body unit including a golf ball receptacle that receives a golf ball and sequentially feeds the golf ball through an outlet, a support for supporting the golf ball receptacle, and a plate extending from the support; an outlet block unit that is disposed on the support so as to rotate upward and open or shut an outlet of the golf ball receptacle; a rotating unit including an arm which has a lower portion rotatably fixed to the support and which rotates by the golf ball received from the golf ball receptacle so as to transport the golf ball to a golf tee, a weight disposed on the inside of a distal end of the arm so that the arm rotates toward the outlet without using power, an elevating member disposed on a central portion of the arm so as to rotate the outlet block unit upward, a seating member for seating the golf ball ejected as the outlet block unit rotates upward, and a hinge disposed at the distal end of the arm 310 so that its end rotates only inward; and a rotation control unit including a balancer that moves up or down in equilibrium depending on whether the rotating unit has transported the golf ball to the golf tee, a connection member that keeps the balancer raised and rotates downward when the golf ball sits on the golf tee, a rotary shaft that is coupled to the connection member and rotates in a direction in which the connection member moves, and a support member that is disposed at a distal end of the rotary shaft, is positioned behind the hinge as it rotates by the golf ball placed on the golf tee in such a way as to prevent the rotating unit from rotating, and returns to its original position when the golf ball falls off the golf tee so that the rotating unit having the golf ball laid thereon rotates toward the golf tee.
The golf ball receptacle may include a first guide including an inclined panel having an inlet at one side thereof and a guide rail tapering down so as to guide the incoming golf ball toward the inlet one at a time, and a second guide that makes contact with only the bottom and left and right sides of the golf ball dropping down into the inlet and is sloped downwardly so as to guide the golf ball to the outlet.
The powerless automatic tee up machine may further include a shock transmitter that limits a radius of rotation of the rotating unit for transporting the golf ball to the golf tee and delivers kinetic energy of the rotating unit to the guide rail.
The shock transmitter delivers shocks produced according to the direction in which the rotating unit moves to the golf ball or the guide rail by contacting a top portion of the arm or the weight.
The shock transmitter passes through a side of the golf ball receptacle. The powerless automatic tee up machine may further include a shock absorber that absorbs a shock by contacting the weight of the rotating unit that rotates toward the golf tee and allows the golf ball to rest on the golf tee at a constant height without bouncing. The position of a portion of the shock absorber in contact with the weight is adjustable.
Advantageous Effects
As described above, a powerless automatic tee up machine according to the present invention enables repeated tee up of golf balls without using power through potential energy of a rotating unit produced by weight of a golf ball and a link system between an outlet block unit that opens or shuts an outlet according to a cam curve of an elevating member and a rotation control unit which controls the motion of the rotating unit in accordance with whether a golf ball has been transferred to a golf tee. The powerless automatic tee up machine also has a simple structure and low manufacturing cost, thereby providing high cost effectiveness.
Another advantage of the powerless automatic tee up machine is to include a shock absorber that absorbs kinetic energy of the rotating unit while teeing up a golf ball so that the golf ball is stably transported onto a golf tee and a shock transmitter which delivers the kinetic energy directly or indirectly to the golf ball and prevents bottlenecks in sequential alignment of golf balls.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a powerless automatic tee up machine according to an embodiment of the present invention,
FIG. 2 is a front view of the powerless automatic tee up machine of FIG. 1 .
FIG. 3 is a side view of the powerless automatic tee up machine having a shock transmitter according to an embodiment of the present invention.
FIG. 4 is a side view of the powerless automatic tee up machine having a shock absorber and a shock transmitter according to an embodiment of the present invention.
FIGS. 5A and 5B illustrate examples of a first guide and a shock transmitter in the powerless automatic tee up machine, according to an embodiment of the present invention.
FIG. 6 illustrates a second guide in the powerless automatic tee up machine, according to an embodiment of the present invention.
FIG. 7 illustrates an outlet block unit in the powerless automatic tee up machine, according to an embodiment of the present invention.
FIG. 8 illustrates a rotating unit in the powerless automatic tee up machine, according to an embodiment of the present invention.
FIGS. 9A and 9B illustrate a balancer in the powerless automatic tee up machine, according to an embodiment of the present invention.
FIG. 10 illustrates a connection structure for connecting a connection member, a rotary shaft, and a support member in the powerless automatic tee up machine, according to an embodiment of the present invention.
FIG. 11 illustrates an operation between a hinge and a support member in a powerless automatic tee up machine, according to an embodiment of the present invention.
FIG. 12 illustrates the operating principle of a shock transmitter in the powerless automatic tee up machine, according to an embodiment of the present invention.
FIG. 13 illustrates a shock absorber in the powerless automatic tee up machine, according to an embodiment of the present invention.
FIGS. 14A through 14C illustrate operation states of the powerless automatic tee up machine according to an embodiment of the present invention.
BEST MODE
Hereinafter, a powerless automatic tee up machine according to an embodiment of the present invention will be described in detail with reference to the attached drawings.
FIG. 1 is a perspective view of a powerless automatic tee up machine according to an embodiment of the present invention. FIG. 2 is a front view of the powerless automatic tee up machine of FIG. 1 . FIG. 3 is a side view of the powerless automatic tee up machine having a shock transmitter according to an embodiment of the present invention. FIG. 4 is a side view of the powerless automatic tee up machine having a shock absorber and a shock transmitter according to an embodiment of the present invention. FIGS. 14A through 14C illustrate operation states of the powerless automatic tee up machine according to an embodiment of the present invention.
Referring to FIGS. 1 through 4 and 14 A through 14 C, the powerless automatic tee up machine according to the present embodiment includes a main body unit 100 which basically accommodates golf balls up to a predetermined height, an outlet block unit 200 that is disposed on the main body unit 100 and determines the state in which a golf ball 1 is ejected, a rotating unit 300 disposed in the main body unit 100 so as to rotate up or down depending on the presence or absence of the golf ball 1 , and a rotation control unit 400 that controls the rotating unit 300 to remain adjacent to the main body unit 100 and stationary in the absence of the golf ball 1 .
The main body unit 100 includes a golf ball receptacle 110 that receives the golf ball 1 and sequentially feeds the golf ball through an outlet 111 , a support 120 provided such that the golf ball receptacle 110 is separated a predetermined height above the ground, and a plate 130 extending from the support 120 .
FIGS. 5A and 5B illustrate examples of a first guide 112 and a shock transmitter 500 in the powerless automatic tee up machine, according to an embodiment of the present invention. FIG. 6 illustrates a second guide 113 in the powerless automatic tee up machine, according to an embodiment of the present invention.
The golf ball receptacle 110 includes the first guide 112 and the second guide 113 . The first guide 112 includes an inclined panel 112 a having a sloped surface to cause the golf ball 1 to roll (toward the outlet 111 ) and an inlet into which the golf ball 1 rolls down its way and drops, and a guide rail 112 b tapering down so as to guide the golf ball 1 on the inclined panel 112 a toward the inlet one at a time. The second guide 113 makes three linear contacts with only the bottom and left and right sides of the golf ball 1 in order to reduce a frictional force and provides a downwardly sloping path so as to sequentially guide the golf ball 1 one at a time before reaching the outlet 111 . The golf ball receptacle 110 may further include the shock transmitter 500 that prevents the golf ball 1 from being stuck on the first guide 11 , which will be described in more detail below.
The support 120 is provided such that the golf ball receptacle 110 is separated a predetermined distance above the ground. The support 120 also provides a space or coupling surface for installing the outlet block unit 200 and the rotating unit 300 . The support 120 is sufficiently high so as to eject the golf ball 1 from the golf ball receptacle 110 through the outlet 111 and convey the golf ball 1 to a golf tee 2 .
The plate 130 extends from a bottom of the support 120 in the same direction as the outlet 111 . The plate 130 supports the golf ball receptacle 110 and the support 120 to stably stand upright and erect and provide a space for horizontally mounting the rotation control unit 400 thereon.
FIG. 7 illustrates the outlet block unit 200 in the powerless automatic tee up machine, according to an embodiment of the present invention.
Referring to FIG. 7 , the outlet block unit 200 opens/shuts the outlet 111 so as to determine whether to eject the golf ball 1 and can rotate upward due to an elevating member 330 that is described in more detail below. The outlet block unit 200 may include a rotation member 210 that is rotatably pin fixed to the support 120 in front of the outlet 111 and an anti-rotation member 220 that prevents the rotation member 210 from moving downward.
FIG. 8 illustrates the rotating unit 300 in the powerless automatic tee up machine of FIG. 1 , according to an embodiment of the present invention.
The rotating unit 300 rotates the outlet block unit 200 upward so that the golf ball 1 is ejected from the golf ball receptacle 110 . As an upper end of the rotating unit 300 rotates toward the ground due to the weight of the golf ball, the golf ball 1 rolls down onto the golf tee 2 and the rotating unit 300 rotates back toward the outlet 111 . The rotating unit 300 continues to perform the same process without using power. To achieve this, the rotating unit 300 includes an arm 310 which has a lower portion rotatably fixed to the support 120 and which rotates due to the weight of the golf ball 1 received from the golf ball receptacle 110 so as to transport the golf ball 1 to the golf tee 2 , a weight 320 disposed on the inside of the lower portion of the arm 310 so that the arm 310 rotates toward the outlet 111 without using power, an elevating member 330 disposed on a central portion of the arm 310 so as to rotate the outlet block unit 200 upward, a seating member 340 for seating the golf ball 1 ejected as the outlet block unit 200 rotates upward, and a hinge 350 disposed on the outside of the lower portion of the arm 310 so that its end rotates inward.
The arm 310 has a throughhole, the diameter of which is longer than that of the golf ball 1 , at an upper end, a long hole connecting with the throughhole along a longitudinal direction so that the golf ball 1 may roll stably toward the throughhole, and a rib shaft-coupled to the support 120 at its lower portion. Thus, when the golf ball 1 is placed on the seating member 340 and the arm 310 rotates toward the ground, the golf ball 1 rolls along the long hole and drops downward through the throughhole.
The weight 320 allows the arm 310 to rotate back toward the golf ball receptacle 110 without using power after the arm 310 has rotated down toward the ground. The weight 320 is appropriately heavy so as to rotate the arm 310 down toward the ground when the golf ball 1 is positioned on the seating member 340 , and to rotate the arm 310 back toward the golf ball receptacle 110 when the golf ball 1 falls off the arm 310 . For example, the weight 320 may be detachably bolt-coupled to a bent L-shaped end of the arm 310 .
The elevating member 330 lifts the outlet block unit 200 so that the golf ball 1 is ejected from the outlet 111 . When the arm 310 rotates toward the outlet 111 , the elevating member 330 produces a cam curve to cause the outlet block unit 200 to open, so that the golf ball 1 is ejected from the outlet 111 . On the other hand, when the arm 310 rotates toward the ground, the outlet 111 is shut due to the unladen weight of the rotation member 330 so that the golf ball 1 is not ejected from the outlet 111 . In this case, the elevating member 330 may be disposed on either side of the arm 310 so as to allow the golf ball 1 to smoothly travel to the ground along the long hole of the arm 310 .
The seating member 340 is provided to stably position the golf ball 1 that is ejected from the outlet 111 when the outlet block unit 200 is rotated upward by the elevating member 330 . That is, the golf ball 1 makes contact with an L-shaped support surface formed by the arm 310 and the seating member 340 (as it passes through the seating member 340 ).
The hinge 350 cooperates with the rotation control unit 400 (to be described below) so as to prevent the rotating unit 300 from rotating toward the ground when the golf ball 1 is positioned on the seating member 340 until the golf ball 1 is removed from the golf tee 2 .
The rotation control unit 400 includes a balancer 410 , a connection member 420 , a rotary shaft 430 , and a support member 440 . The balancer 410 is disposed below the rotation control unit 400 and moves up or down in equilibrium depending on whether the rotating unit 300 has transported the golf ball 1 to the golf tee 2 . The connection member 420 keeps the balancer 410 raised when the golf ball 1 does not sit on the golf tee 2 and rotates downward when the golf ball 1 sits on the golf tee 2 . The rotary shaft 430 is coupled to the connection member 420 and rotates in a direction in which the connection member 420 moves. The support member 440 is disposed at a distal end of the rotary shaft 430 and is positioned behind the hinge 350 as it is rotated when the golf ball 1 placed on the golf tee 2 so as to prevent the rotating unit 300 from rotating further. When the golf ball 1 falls off the golf tee 2 , the support member 440 returns to its original position so that the rotating unit 300 having the golf ball 1 laid thereon rotates toward the golf tee 2 .
FIGS. 9A and 9B illustrate the balancer 410 in the powerless automatic tee up machine, according to an embodiment of the present invention.
The balancer 410 includes a horizontal panel 411 on which the golf tee 2 is positioned, a pair of opposing first clamping ribs 412 disposed on a bottom surface of the horizontal panel 411 , a balancing member 413 that is detachably coupled to the pair of first clamping ribs 412 in a diagonal direction and allows the horizontal panel 411 to move up and down, and a pair of second clamping ribs 414 that are disposed on the plate 130 and fix the balancing member 413 . The balancer 410 having the above-described structure moves up or down in equilibrium within a range of movement of the balancing member 413 and is combined with the connection member 420 so as to limit the movement of the rotating unit 300 under control of the support member 440 . In this case, the connection member 420 may be simply welded to the balancer 410 or be detachably secured to pass through one or more clamping ribs 415 on the bottom surface of the horizontal panel 411 .
FIG. 10 illustrates a connection structure for connecting the connection member 420 , the rotary shaft 430 , and the support member 440 in the powerless automatic tee up machine, according to an embodiment of the present invention.
When the golf ball 1 is not placed on the golf tee 2 , the connection member 420 keeps the balancer 410 raised according to the connection structure for connecting the rotary shaft 430 and the support member 440 . Conversely, when the golf ball 1 is placed on the golf tee 2 , the balancer 410 is lowered, and simultaneously the connection member 420 rotates in one direction and is coupled to the rotary shaft 430 so as to control the movement of the rotating unit 300 .
The rotary shaft 430 has one end coupled to the connection member 420 , the other end fixed to the support member 440 , and the remaining portion rotatably fixed to the plate 130 and robustly supported. Thus, the rotary shaft 420 rotates in the same direction that the connection member 420 rotates.
FIG. 11 illustrates the relationship between the operation of the hinge 350 and the support member 440 in the powerless automatic tee up machine, according to an embodiment of the present invention.
When the golf ball 1 is not placed on the golf tee 2 , the support member 440 cooperates with the rotary shaft 430 and the connection member 420 so as to keep the balancer 410 in an elevated position due to greater weight on the outside. When the golf ball 1 is placed on the golf tee 2 , the support member 440 rotates toward the hinge 350 so as to prevent the rotating unit 300 from rotating toward the golf tee 2 . Because a portion of the hinge 350 rotates only inward, the rotating unit 300 maintains the state in which the golf ball 1 is ejected using the arrangement between the hinge 350 and the support member 440 when the golf ball 1 is placed on the golf tee 2 . When the golf ball 1 is removed from the golf tee 2 , the support member 440 returns to its original position so that the rotating unit 300 transports the golf ball 1 to the golf tee 2 .
Because a distance between opposing guide rails 112 b of the first guide 112 decreases downward, the golf ball 1 may not be smoothly delivered to the second guide 113 due to bottlenecks. Thus, to solve this problem, the powerless automatic tee up machine according to the present embodiment further includes the shock transmitter 500 that limits a radius of rotation of the rotating unit 300 for transporting the golf ball 1 to the golf tee 2 and delivers kinetic energy of the rotating unit 300 to the guide rail 112 b . The first guide 112 may be shaft fixed or bolted to the golf ball receptacle 110 so as to be agitated by shocks delivered by the shock transmitter 500 .
FIG. 12 illustrates the operating principle of the shock transmitter 500 in the powerless automatic tee up machine, according to an embodiment of the present invention. FIG. 13 illustrates a shock absorber 600 in the powerless automatic tee up machine, according to an embodiment of the present invention.
The shock transmitter 500 may have two structures to deliver shocks produced according to the direction in which the rotating unit 300 moves to the golf ball 1 by contacting a top portion of the arm 310 or the weight 320 . As shown in the drawings, when the top portion of the arm 310 is directed toward the inlet 111 , a portion of the shock transmitter 500 may pass through a side of the golf ball receptacle 110 and apply a shock to the guide rail 112 b or directly to the golf ball 1 that is stuck due to bottlenecks. In this case, the shock transmitter 500 may have a spring at a distal end or may be shaft-coupled (to the golf ball receptacle 110 ) so that it moves back to its original position due to the weight after the golf ball 1 is hit off the golf tee 2 . In another structure, in order to limit the movement of the weight 320 when the arm 310 rotates toward the golf tee 2 , one end of the shock transmitter 500 passes through a bottom surface of the golf ball receptacle 110 and is coupled to the guide rail 112 b while the other end thereof contacts the weight 320 .
When the shock transmitter 500 is used, the powerless automatic tee up machine according to the present embodiment may further include the shock absorber 600 that absorbs a shock by contacting the weight 320 of the rotating unit 300 that rotates toward the golf tee 2 and allows the golf ball 1 to rest on the golf tee 2 at a constant height without bouncing. The shock absorber 600 may also adjust the position of its portion in contact with the weight 320 , thereby allowing precise placement of the golf ball 1 on golf tees having different heights. Referring to FIG. 13 , the shock absorber 600 for adjusting its position includes a contact portion 610 which contacts the weight 320 and rotates within a predetermined range in order to absorb shocks, a fastening member 620 fixed to the inside of the support 120 , and a shaft bolt 630 . In order to adjust the position, the contact portion 610 may be shaft fixed to the fastening member 620 at different positions by inserting the shaft bolt 630 . That is, the position of the contact portion 610 may be adjusted depending on the position at which the shaft bolt 630 is engaged with a nut. Alternatively, the contact portion 610 may be raised or lowered by varying the length of an adjustment bolt passing through the support 120 . | The present invention relates to a powerless automatic tee up machine, which repeats the transporting of the golf balls onto a golf tee through potential energy, a cam curve, a principle of balancer and a link system without using power, and which has a maximally simplified structure to significantly reduce manufacturing costs as compared to conventional machines. For this purpose, the powerless automatic tee up machine of the present invention comprises a main body unit which receives a golf ball and feeds the gold ball through an outlet, an outlet block unit for opening/shutting the outlet, a rotating unit which determines the opening/shutting operation of the outlet block unit, and which rotates in accordance with the presence or absence of the golf ball, and a rotation control unit which controls the motion of the rotating unit in accordance with whether or not the golf ball has been transferred to a golf tee by the rotating unit, thereby enabling the repeated tee up of golf balls without using power and also increasing effectiveness in terms of manufacturing costs due to the simplified structure. | 0 |
CROSS-REFERENCE TO CO-PENDING PATENT APPLICATIONS
This Nonprovisional Patent application is a continuation-in-part of Provisional Patent Application No. 61/175,949, filed on May 6, 2009 by inventor Hector Martinez hereby incorporated by reference in its entirety and for all purposes, to include claiming benefit of the priority data of filing of Provisional Patent Application No. 61/175,949.
FIELD OF THE INVENTION
The present invention relates to the field of biological waste and toxic material collection and management. The present invention more particularly relates to the collection and transfer of solid waste and toxic material.
BACKGROUND OF THE INVENTION
Solid waste and solid toxic materials are generated from many sources, to include by production and evacuation from animals as well as industrial processes. Farm laborers, zoo workers and pet owners are not unusually tasked with cleaning up waste matter or from the ground or otherwise deposited by animals, such as canines, cats, domesticated animals and/or animals maintained in confined areas.
Yet touching feces is almost universally repulsive and considered to be a degrading and undesirable act. The prior art includes efforts to maintain separation between a collector of animal waste or toxic matter and the material to be collected.
To solve the above stated problem it has been proposed to collect the pet's excrement by means of small shovels, placing the depositions into bags that when closed are discarded into any street or public trash collector.
U.S. Pat. No. 6,059,332 discloses a domestic pet's excrement collector. The invented collector includes two similar rectangular structures facing each other and joined in between by a posterior concave-convex wall forming a pincer-shaped hinge for the collector. Over the convex face of the wall is fixed a cylindrical tube closed at one end, having inside of the tube a roll of continuous bags, while the other end of the tube is closed by a lid. The plastic bag is placed covering the collecting pincers. The bottom of the bag is contained within the pincers towards the cylindrical tube. This complex construction does not relate to the present invention.
U.S. Pat. No. 7,523,972 discloses a portable waste remover with integrated bag. The invented waste remover includes a handle, a housing portion for holding and dispensing bags, and a grabbing assembly actuated by a spring and pulley assembly contained in the handle. The grabbing assembly is further coupled to a first and second frame member wherein the frame members are capable of pivotally attachment to the housing portion. The first and second pivot arms may have removable clamps that either secure the frame members for grabbing waste or detach from the frame members making them collapsible. The housing portion may be configured in the shape of a tube with a roller and having a slotted groove disposed where disposable bags may be fitted around the roller and dispensed through the slotted groove. In another configuration, the grabber assembly engaging the handle is comprised of a button, spring, spring arm with shoulder, and toothed elongated arm engaging the frame members.
There is a long-felt need to provide a device that optimally enables a human to collect animal solid waste, or other solid toxic material, without requiring the device operator to handle or touch the solid material.
None of the mentioned prior-art patents offers a construction similar to this present invention, nor provide a solution having a low cost base structure or frame including a movable arm, to which is attached a disposable plastic bag within which the pet's depositions are collected, such as disclosed herein. Once the bag has been used, the bag may be withdrawn in a rapid and hygienic manner.
SUMMARY OF THE INVENTION
This and other objects of the present invention are made obvious in light of this disclosure, wherein a device is provided for collecting and bagging solid waste is provided. According to a first device, a first arm and a second arm are coupled with a lever, wherein at least one arm is slidably coupled with the lever. A bag may be positioned in an open position when the first arm is located distally from the second arm, and the bag may be closed by a device user manipulating the arms towards each other.
The first device may optionally include a motor that provides mechanical force applicable to drives the arms towards and/or away from each other. Additionally or alternatively, an optional spring or springs may be attached to the arms or lever to drive the arms towards and/or away from each other.
In alternate devices, the mechanical force applied to drive the arms towards and/or away from each other may be translated to one or both arms by a chain or a cable element.
In still alternate devices, plate, a pole and/or a handle may be coupled with the arms. The plate is positioned relative to the arms to stabilize the waste or toxic material for insertion into the bag. The pole and/or handle may be configured to reduce or eliminate the degree of bending required by the device user during the process of collected waste or toxic material.
In certain alternate variations, the bag may include paper, plastic, recycled plastic, vegetable matter and/or cellulose. Alternatively or additionally, the bag further includes an internal adhesive proximate an aperture of the bag.
In certain still alternate variations, the bag maintains a barrier between the device and keeps the waste material from contaminating or touching the device. A handle for the device may allow the user to collect and package the waste material in a bag without directly touching the waste material. Soiling of the user's hands, skin, footwear or clothing by the waste can thus be avoided.
The foregoing and other objects, features and advantages will be apparent from the following description of aspects of the present invention as illustrated in the accompanying drawings.
INCORPORATION BY REFERENCE
All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited. All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference in their entirety and for all purposes to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.
Such incorporations include U.S. Pat. No. 4,196,365 (Inventor: Presley, D.; issued on Apr. 1, 1980) titled “Magnetic motor having rotating and reciprocating permanent magnets”; U.S. Pat. No. 4,878,869 (Inventor: Yuji Yamane et al.; issued on Nov. 7, 1989) titled “Toys having magnetic switches”; U.S. Pat. No. 6,059,332 (Inventor: Beascoechea Inchaurraga; Issued on May 9, 2000) titled “Collector for excreta from domestic animals”; U.S. Pat. No. 7,095,155 (Inventor: Takeuchi, K.; issued on Aug. 22, 2006) titled “Motor and drive control system thereof”; U.S. Pat. No. 7,523,972 (Inventor: Wawrzynowski, Michael; Issued on Apr. 28, 2009) titled “Portable waste remover with integrated bag”; and U.S. Pat. No. 7,216,905 (Inventor: Armes, Jr., A.; Issued on May 15, 2007) titled “Refuse removal system and method for removing refuse”.
The publications discussed or mentioned herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Furthermore, the dates of publication provided herein may differ from the actual publication dates which may need to be independently confirmed.
BRIEF DESCRIPTION OF THE FIGURES
These, and further features of various aspects of the present invention, may be better understood with reference to the accompanying specification, wherein:
FIG. 1A illustrates a bag having pocket, two flaps and a plurality of optional adhesive strips;
FIG. 1B is a side view of the bag of FIG. 1A ;
FIG. 1C is a front view of the bag of FIGS. 1A and 1B containing a waste material sealed in the pocket by one or more adhesive strips;
FIG. 2 is a perspective view of a waste capturing device, or “scooper”, in an open position;
FIG. 3 is a perspective view of the scooper of FIG. 2 with the bag of FIGS. 1A-1C attached and partially enclosing a waste material;
FIG. 4 is a perspective view of the scooper of FIGS. 2 and 3 in a closed positioned, wherein the waste material is substantially enclosed in the pocket of the bag of FIGS. 1A-1C and 3 ;
FIG. 5 is a first alternate variation of the present variation that includes a pole attached to the scooper;
FIG. 6 is a schematic diagram of electromechanical aspects of the scooper of FIGS. 2-5 ;
FIG. 7 is a perspective view of the scooper of FIGS. 2-6 in a travel position; and
FIG. 8 is a schematic of a second alternate variation of the present invention of FIGS. 1-6 wherein a spring-actuated mechanism is provided.
DETAILED DESCRIPTION
It is to be understood that this invention is not limited to particular aspects of the present invention described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
Methods recited herein may be carried out in any order of the recited events which is logically possible, as well as the recited order of events.
Where a range of values is provided herein, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits ranges excluding either or both of those included limits are also included in the invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, the methods and materials are now described.
It must be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely,” “only” and the like in connection with the recitation of claim elements, or use of a “negative” limitation.
Referring now to FIG. 1A a bag 2 is formed by a first sheet 4 A and a second sheet 4 B joined along a seam 6 from a first joining point 8 to a second joining point 10 . The bag 2 may be or comprise paper, plastic, recycled plastic, vegetable matter and/or cellulose. Alternatively or additionally, the bag 2 may be or comprise polyethylene or other suitable plastic material known in the art.
A first flap 12 is comprised of a portion of the first sheet 4 A extending from the first joining point 8 and the second joining point 10 . A second flap 14 is comprised of a portion of the second sheet 4 B extending from the first joining point 8 and the second joining point 10 . An open pocket 16 is formed defined by the seam 6 . One or more internal adhesive strips 18 A of the first flap 12 and/or one or more internal adhesive strips 18 B of the second flap 14 are located on an internal side 19 of the bag 2 . Additionally, alternatively of optionally one or more external adhesive strips 20 A- 20 D are located an external side 21 of either or both the first flap 12 and/or the second flap 14 of the bag 2 .
The clips may be or comprise a binder clip product number LOP13351 as marketed by Legacy Office Products of Indianapolis, Ind.
The pocket 16 extends from an opening 17 and away from the first flap 12 and the second flap in a depth dimension D. The opening 17 extends from the first joining point 8 and the second joining point 10 . The first flap 12 and the second flap 14 extending from the opening 17 and away from the pocket 16 along the depth dimension D.
The first flap 12 and the second flap 14 preferably extend, in various alternate preferred embodiments of the present invention, for a linear length along the depth dimension D selected from the depth range of from one inch to two feet and away from the pocket 16 .
The pocket 16 preferably extends, in various yet alternate preferred embodiments of the present invention, along the depth dimension D for a linear length selected from the range of from one inch to two feet and away from the opening 17 , the first flap 12 and the second flap 1 .
The pocket 16 , first flap 12 and/or the second flap 14 preferably extend for a linear length of from one inch to two feet along a width dimension W in various even alternate preferred embodiments of the present invention, wherein the width dimension W is orthogonal to the depth dimension D.
In various other additional alternate preferred embodiments of the present invention, the pocket 16 , first flap 12 and/or the second flap 14 preferably extend for a linear length selected from the range of from one inch or less or two feet or more along the width dimension W and/or the depth dimension D. In various still additional alternate preferred embodiments of the present invention, the pocket 16 , first flap 12 and/or the second flap 14 preferably extend for a linear length selected from the range from 0.1 or less to more than two feet along the width dimension W and/or the depth dimension D.
Referring now to FIG. 1B is a side view of the bag 2 of FIG. 1A , where in the first flap 12 and the second flap 14 are separated and the pocket 16 is partially open. The seam 6 maintains the integrity of the pocket 16 in both an open and a closed position.
It is understood that the seam 6 may be formed with an adhesive (not shown) or a heating and a compression of the first sheet 4 A and the second sheet 4 B. It is further understood that the bag 2 may be formed without the seam 6 and according to suitable means known in the art.
Referring now to FIG. 1C is a front view of the bag 2 of FIGS. 1A and 1B containing a waste material 22 sealed in the pocket 16 by one or more internal adhesive strips 18 A. The pocket 16 is thus defined by the seam 6 and a seal formed by a first internal adhesive strip 18 A and a second adhesive strip 18 B, and the first flap 12 and the second flap 14 extend away from the pocket 16 for more acceptable handling of the bag 2 as it encloses the waste material 22 .
The waste material 22 may be or comprise animal feces, toxic waste, biological matter, industrial waste, vegetable matter, and/or unwanted or undesired material or substance in combination or singularity.
Referring now to FIG. 2 is a perspective view of a waste capturing device 24 , or “scooper” 24 , in an open position. An arm 26 and a plate 28 are configured to allow the arm 26 to be positioned distally from the plate 28 and a housing 30 by movement of a linear actuator 32 (hereinafter, “lever” 32 ). The arm 26 and the lever 32 are coupled by an arm hinge assembly 34 , wherein the arm hinge assembly 34 enables the arm to be rotated along a Y-axis. The plate 28 and the housing 30 are coupled by a plate hinge assembly 36 , wherein the plate hinge assembly 36 enables the plate 28 to be rotated about a Y-axis. The X-axis and the Y-axis are mutually orthogonal to each other and, both the Y-axis and the Z-axis are mutually orthogonal to a third Z-axis.
A three state actuation button 38 enables the actuation of a process of positioning the arm 26 relative to the plate 28 as described herein.
One or more elements 26 - 38 of the scooper 24 consist of, or comprise, aluminum, iron, stainless steel or other suitable metal, metal alloy or material known in the art. Additionally or alternatively, one or more elements 26 - 38 of the scooper 24 may consist of, or comprise polystyrene, polyvinyl chloride, polyethylene, polypropylene, or other suitable thermoplastic polymer or plastic polymer known in the art.
Preferably the scooper 24 has a total weight of less than five pounds. More preferably the scooper 24 has a total weight of less than two pounds and more than 0.25 pounds. Most preferably the scooper 24 has a combined weight of less than one pound.
Preferably the scooper 24 has a total weight of less than five pounds. More preferably the scooper 24 has a total weight of less than two pounds and more than 0.25 pounds. Most preferably the scooper 24 has a combined weight of less than one pound.
In certain applications, preferably the scooper 24 is shaped to fit within a three dimensional volume of less than 0.500 cubic feet. In alternate applications and certain other alternate preferred embodiments, the scooper is preferably shaped to fit within a volume defined when the arm 26 is fully extended in by the limits of less than two foot along the X-axis, one foot along the Y-axis, and less than one foot along the Z-axis.
In various alternate preferred embodiments, the arm 26 comprises a shovel plate that (as deployed in the open position of the device 24 ) has a first dimension along y-axis between eight inches and one inch, a second dimension along the Z-axis between eight inches and one inch, and a third dimension along the X-axis of less than 0.25 inches; and/or the plate 28 comprises an flat element that has a first dimension between eight inches and one inch, a second dimension between eight inches and one inch, and a third dimension of less than 0.25 inches.
The bag 2 is sized and shaped to present an opening when attached the scooper 24 that is approximately as long as the first dimension or second dimension of the plate 28 . The first flap 12 and the first flap 14 may be configured to be as wide along the W axis as the first dimension or second dimension of the plate 28 or the arm 26
Referring now to FIG. 3 is a perspective view of the scooper 24 of FIG. 2 with the bag of FIGS. 1A-1C attached and partially enclosing a waste material 22 . The first flap 12 is held to the arm 26 by a first clip 40 and or one or more external adhesive strips 20 A- 20 D. The second flap 14 is held to the arm 26 by a second clip 42 and or one or more external adhesive strips 20 A- 20 D. The pocket 16 is positioned proximate to and substantially around the waste material 22 .
Referring now to FIG. 4 is a perspective view of the scooper 24 of FIGS. 2 and 3 in a closed positioned, wherein the waste material 22 is substantially enclosed in the pocket 16 . The arm 26 is driven forward along the X-axis and causes the material 22 to be captured by the pocket 16 . One or more internal adhesive strips 18 A and 18 B create and maintain a sealed edge of the pocket 16 .
Referring now to FIG. 5 is a first alternate variation of the present variation that allows a user 44 to grasp a handle 46 of a pole 48 , wherein the pole 48 is attached to the housing 30 of the scooper 24 . The pole 48 may be configured with a linear length L extending for a length in the range from six inches to five feet in various alternate configurations. Preferably the pole 48 presents a cross-sectional diameter in a plane normal to the linear length L in the range of two inches to 0.25 inches. More preferably the pole 48 presents a cross-sectional diameter in a plane normal to the linear length L in the range of one inch to 0.5 inches. Preferably the handle 46 presents a cross-sectional diameter in a plane normal to the linear length L in the range of one inch to 0.25 inches. More preferably the handle presents a cross-sectional diameter in a plane normal to the linear length L in the range of one inch to 0.5 inches.
One or more elements 26 - 38 of the handle 46 and the pole 48 may be consist of, or comprise, aluminum, iron, stainless steel, or other suitable metal, metal alloy or material known in the art. Additionally or alternatively the handle 46 and pole 48 may consist of, or comprise polystyrene, polyvinyl chloride, the polyethylene and polypropylene, or other suitable thermoplastic polymer or plastic polymer known in the art. Preferably the scooper 24 , pole 48 and handle 46 have a total combined weight of less than five pounds. More preferably the scooper 24 , pole 48 and handle 46 have a total combined weight of less than two pounds and more than 0.25 pounds. Most preferably the scooper 24 , pole 48 and handle 46 have a combined weight of less than one pound.
Referring now to FIG. 6 is a schematic diagram of electromechanical aspects of the scooper 24 of FIGS. 2-5 . An electric battery 50 provides electrical power to an electromagnet assembly 52 and a control circuit 54 . The control circuit 54 is coupled to the control button 38 and the control circuit 54 is configured to cause the electromagnet to spin a magnet 56 of a circular gear 58 to rotate in either a clockwise or a counter clockwise rotation in reference to rotation about the Y-axis.
The battery 50 , the electromagnetic assembly 52 , the control circuit 54 , the magnet 56 and the circular gear 58 are coupled to the housing 30 .
The circular gear 58 engages with a plurality of teeth 60 of the lever 32 , thereby translating the rotational motion about the Y-axis of the circular gear 58 into linear motion along the X-axis. The resultant linear motion of the lever 32 along the X axis causes the arm 26 to move toward or away from the plate 28 , whereby the scooper translates to and from open position as illustrated in FIGS. 2 and 3 and to the closed positioned of FIG. 4 .
One or more elements 50 - 60 of the scooper 24 consist of, or comprise, a magnetized metal, aluminum, iron, stainless steel or other suitable metal, metal alloy or material known in the art. Additionally or alternatively, one or more elements 26 - 38 of the scooper 24 may consist of, or comprise polystyrene, polyvinyl chloride, polyethylene, polypropylene, or other suitable thermoplastic Polymer or plastic polymer known in the art.
The control, button 38 is a three position control that the user 44 manually positions in an off state, a second state and a third state. When the control button 38 is in the off state the control circuit 54 either electrically disconnects or fails to electrically connect the battery 50 to the electromagnet assembly 52 . When the control button 38 is in the second state, the control circuit 54 electrically connects the battery 50 to the electromagnet assembly 52 and/or directs the circular gear 58 to rotate in a first rotational direction about the Y-axis that causes the lever 32 to extend out from the housing 30 along the X-axis, and thereby position the arm 28 in the open position. disconnects or fails to electrically connect the battery 50 to the electromagnet assembly 52 . When the control button 38 is in the third state, the control circuit 54 electrically connects the battery 50 to the electromagnet assembly 52 and/or directs the circular gear 58 to rotate in a second rotational direction about the Y-axis that causes the lever 32 to move into the housing 30 along the X-axis, and thereby position the arm 28 in the closed position.
The circular gear 58 may be rotatably coupled to a fixed axle 61 , wherein the axle 61 is coupled with housing 30 and a magnet field generated by the electromagnet assembly 52 acts upon the magnet 56 to drive the magnet 54 around the axle 61 and thereby cause the circular gear 58 to rotate about the axle 61 . The circular gear 58 engages with the teeth 60 of the lever 32 as the circular gear 58 rotates and thereby drives linear motion of the lever 32 .
Alternatively the circular gear 58 may be driven as controlled by the control circuit 54 and by a Kinmore™ electric toy motor model number KM-16T050 as marketed by Shenzhen Kinmore Motor Co. Ltd. of Nanshan District, Shenzhen, Guangdong, People's Republic of China.
Referring now to FIG. 7 is a perspective view of the scooper 24 of FIGS. 2-6 in a travel position, wherein the arm 26 and the plate 28 are each positioned to align substantially parallel to an X-Y plane defined by the X-axis and the Y-axis. The positioning of the arm 26 toward the X-Y plane orientation is facilitated by the arm hinge assembly 34 , and the positioning of the lever 28 toward the X-Y plane orientation is facilitated by the plate hinge assembly 36 . An optional manual handle 62 further increases the ease with which the scooper 24 may be transported.
Referring now to FIG. 8 is a schematic of a second alternate variation of the present invention of FIGS. 1-6 wherein a spring-actuated mechanism is provided. A spring 64 is coupled to the housing 30 by a spring guide 66 . The spring guide 66 is coupled to the housing at a first guide point 66 A and a second guide point 66 B. A trigger 68 is rotatably coupled to the housing 30 by a rotational coupling 70 , and may be rotated to maintain the arm 26 in the open position of FIGS. 2 and 3 . The spring 64 directs a spring force to the arm 26 to cause the arm 26 to move along the X-axis and toward the plate 28 and to assume the closed position of FIG. 4 . The user 44 manually rotates the trigger 68 by pressing the trigger end 72 in the up or down direction. Pressing the trigger end 72 in the up direction causes the trigger to enable a maintenance of the arm 26 in the open position of FIGS. 2 and 3 . Pressing the trigger end 72 in the down position causes the trigger 68 to rotate and to enable the spring 64 to drive the arm 26 towards the plate 28 and form the closed position of FIG. 5 .
The foregoing disclosures and statements are illustrative only of the present invention, and are not intended to limit or define the scope of the present invention. The above description is intended to be illustrative, and not restrictive. Although the examples given include many specificities, they are intended as illustrative of only certain possible applications of the present invention. The examples given should only be interpreted as illustrations of some of the applications of the present invention, and the full scope of the Present Invention should be determined by the appended claims and their legal equivalents. Those skilled in the art will appreciate that various adaptations and modifications of the just-described applications can be configured without departing from the scope and spirit of the present invention. Therefore, it is to be understood that the present invention may be practiced other than as specifically described herein. The scope of the present invention as disclosed and claimed should, therefore, be determined with reference to the knowledge of one skilled in the art and in light of the disclosures presented above. | A device for collecting and packaging solid waste or toxic material is provided. A first arm and a second arm are coupled with a lever, wherein at least one arm is slidably coupled with the lever. A bag may be positioned in an open position when the first arm is located distally from the second arm, and the bag may be closed by an operator manipulating the arms towards each other. The device may include a motor or a spring or springs to drive the arms towards or away from each other. A plate, a pole and a handle may be coupled with the arms. The plate may be positioned relative to the arms to stabilize the waste or toxic material for insertion into the bag. The bag may include an adhesive, paper, plastic, recycled plastic, cellulose in combination or singularity. | 4 |
This application is a continuation-in-part of application of Ser. No. 557,261 filed Jul. 24, 1990, now U.S. Pat. No. 5,050,981.
BACKGROUND OF THE INVENTION
This invention is a method for designing a lens to provide an optimal corrective lens-eye system having minimal image aberrations and the resulting lens having an aspheric surface for use as an contact, intraocular or spectacle lens, particularly a lens in which the surface has a hyperbolic or parabolic curvature.
The curvature of a conventional lens surface may be described in terms of "conic sections." The family of conic sections includes the sphere, parabola, ellipse, and hyperbola. All rotationally symmetric conic sections may be expressed in terms of a single equation: ##EQU1## where X is the aspheric surface point at position Y, r is the central radius, and the kappa factor, κ, is the aspheric coefficient.
Other conic constants or aspheric coefficients include the eccentricity, e, which related to κ by the equation κ=-e 2 , and the rho factor, ρ, defined as (1-e 2 ).
The value of the aspheric coefficient determines the form of the conic section. For a sphere, e=0 and κ=0. An ellipse has an eccentricity between 0 and 1 and a κ between 0 and -1. A parabola is characterized by an e=1 (κ=-1). For a hyperbola, e is greater than 1 and κ is less than negative one.
Conventionally, most lens surfaces are spherical or near-spherical in curvature. Theoretically, for an infinitely thin lens, a spherical curvature is ideal to sharply focus the light passing through the lens. However, the curvatures and thicknesses of a real lens produce well-known optical aberrations, including spherical aberration, coma, distortion, and astigmatism; i.e., light from a point source passing through different areas of the lens that does not focus at a single point. This causes a certain amount of blurring. Furthermore, purely spherical lenses are not suitable for correcting astigmatic vision or for overcoming presbyopia.
For this reason, many different types of lenses have been designed for the purpose of minimizing spherical aberration, correcting ocular astigmatism, or providing a bifocal effect that allows the nonaccommodative eye to see objects both near and far. Unfortunately, current designs suffer from serious drawbacks, such as producing blurred or hazy images, or inability to provide sharp focusing at every visual distance.
Aspheric lenses having elliptical surfaces have been used to reduce optical aberrations. Some well known examples are the use of parabolic objective mirrors in astronomical telescopes and the use of ellipses of low eccentricity to correct for aberrations of a contact lens.
The design of an aspheric lens in isolation is well known. There are a variety of commercially available software packages that use variations of the above equation to generate aspheric lens designs. An example of these are: Super OSLO by Sinclair Optics, Inc., Code-V by Optical Research Associates and GENII-PC by Genesee Optics, Inc. These optical design programs are the most widely used packages available. Despite the different approaches used by the three methods, all packages have yielded identical results in aspheric lens design calculations. When used alone for vision correction, carefully designed elliptical lenses do provide an improved focus. However, when used in a system including the human eye, elliptical lenses are not significantly better than spherical lenses. This is because the eye contains a greater amount of aberration than the elliptical lens is able to correct as part of the overall corrective lens-eye system.
Methods used in the past to produce corrective lenses for the eye have resulted in lenses that are non-spherical. In U.S. Pat. No. 4,170,193 to Volk a lens is described which corrects for accommodative insufficiency by increasing dioptric power peripheralward. While this lens and other prior lens designs are not strictly spherical, it is not a pure asphere, and includes higher order deformation coefficients. This yields a surface which is radically different than that proposed herein. A flattening curve, such a hyperbola, would show a slight dioptric decrease peripheralward. Prior lens designs, while attempting to solve various optical problems by varying from a strictly spherical lens design, do not strive for improved vision by reducing the aberration of the image that strikes the retina of the eye.
An important reason for the common use of lens designs that have the above-noted limitations is the failure to take into account the effects of the entire lens eye system. Lenses are usually designed as if the lens would be the only element that contributes to image aberrations, but there are may elements in the eye that affect image focus, such as the surfaces of the cornea and of the eye's natural lens. While the elliptical form was useful in reducing aberrations of the lens itself, when the lens is placed into a system containing all of the refracting surfaces of the human eye additional aspherical correction is required.
SUMMARY OF THE INVENTION
The present invention is that this required correction has been found to be in the form of certain ellipse or a parabola and provides a lens for effectively focusing light on the retina of the eye and a method for producing such lens. The lens has a rotationally symmetric aspheric surface in the form of a ellipse or parabola defined by the equation: ##EQU2## where X is the aspheric surface point at position Y, r is the central radius, and κ is a commonly used aspheric constant, wherein the value of κ is less than or equal to -0.5.
It is an object of the present invention to provide a method for the systematic approach to the design of an aspheric lens in which the lens is considered and optimized as part of the entire corrective lens-eye system.
It is a further object of the present invention to use the modulation transfer function (the modulation scale from black and white to gray) and the spatial frequency (showing the degree to which objects of increasing spatial frequency can be resolved) to optimize a corrective lens design when considered with the corrective lens-eye system.
An additional object of the present invention is to provide a method that produces a lens that optimizes the focusing of an image on the retina of the eye and that minimizes image aberrations and blurring.
It is an object of the present invention to provide a novel aspheric lens design suitable for use in a contact lens, an intraocular lens, or a spectacle lens.
It is also an object of the present invention to provide a lens for use on the surface of, in or near the human eye wherein a lens surface is curved in the shape of a hyperbola.
It is a further object of the present invention to provide a lens for use on the surface of, in or near the human eye wherein a lens surface is curved in the shape of an ellipse or a parabola.
Another object of this invention is to provide an aspheric lens suitable for use by those suffering from presbyopia, myopia, hyperopia, astigmatism, or other vision focusing deficiencies.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation of a contact lens according to the present invention.
FIG. 2 is a cross sectional view of the lens shown in FIG. 1 taken along the line 2--2.
FIG. 3 is a front elevation of an intraocular lens according to the present invention.
FIG. 4 is a cross section view of the lens shown in FIG. 3 taken along the line 4--4.
FIG. 5 graphically compares the size of the retinal image of a point light source as a function of pupil diameter for a myopic eye/hyperbolic contact lens system to that of a myopic eye/spherical contact lens system and an emmetropic eye, where each lens has the optimum optical power to correct the myopia of the eye.
FIG. 6 shows the best focus position relative to the retina for the images of FIG. 5.
FIG. 7 graphically compares the curvature of a spherical surface and an aspheric surface having the same central or apical radius.
FIG. 8 is a typical Modulation Transfer Function graph showing the resolving power of the eye with a conventional corrective lens and the inherent limit of resolving power due to diffraction limits.
FIGS. 9A through F compare the modulation transfer frequency to the diffraction limit in a lens-myope system. Each figure presents the comparison for a particular kappa factor, ranging from κ=0 in FIG. 9A to κ=-2.5 in FIG. 9F.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention applies optical ray trace techniques to an optical schematic of the human eye to achieve heretofore unobtained performance from a corrective len-eye system. The human eye model was developed after an extensive literature search on the subject of human ocular physiology, physiological optics and anatomy. In particular, a starting point for the model were the Gullstrand (1862-1930) Schematic Eyes. Gullstrand created these models on the basis of available data on the anatomy of the eye generated by himself as well as other researchers. The Gullstrand eyes contain centered, spherical surfaces, and were used throughout the 20th century to evaluate first order (i.e., location, not level of aberration) image formation of the human eye.
It is recognized that there are individual variations from the averages which Gullstrand presented, and in addition, advances in metrology allowed analysis in greater detail of the refractive index distribution, as well as variations in aspheric curvature of the various elements. Using the Gullstrand Schematic as a starting point, with the addition of more modern knowledge about the anatomy of the eye, a composite eye model was generated.
To first order, the model can be looked at as a three lens compound system, the lenses being the corrective lens devices, the cornea, and the crystalline lens of the eye. This can be further broken down to contain 13 surfaces for the purpose of ray trace analysis. These surfaces are:
1] Object
2] Front surface of the corrective lens
3] Back surface of the corrective lens
4] Tear layer
5] Corneal epithelium
6] Corneal endothelium aqueous interface
7] Pupil in aqueous
8] Lens anterior cortex
9] Lens anterior core
10] Lens posterior core
11] Lens posterior cortex
12] Vitreous
13] Retina
It is not usual that the image falls on the retina. Indeed, this is the definition of refractive error. Using ray trace techniques, the actual position relative to the retina and quality of the image can be determined.
FIGS. 1 and 2 illustrate one embodiment of a lens 1 according to this invention which is suitable for use as a contact lens. This lens 1 has a rotationally symmetric hyperbolic surface 2 and a concave spherical surface 3. The spherical surface 3 has a radius of curvature which conforms to that of the outer surface of the human eye so that the lens 1 may rest comfortably on the eye surface. The size of the contact lens 1 should be suitable for the intended use, e.g., about 12-15 mm in diameter and no more than about 0.050-0.400 mm thick.
FIGS. 3 and 4 illustrate an intraocular lens 4 according to this invention. This lens 4 has a rotationally symmetric hyperbolic surface 5 and a convex spherical surface 6. The intraocular lens 4 should be approximately 4-7 mm in diameter and have a maximum thickness of about 0.7-1.0 mm.
The lenses of this invention are not limited to the physical dimensions given above; these dimensions are only rough guidelines. A lens may be whatever size is suitable for the intended use.
A lens according to this invention may have two symmetric aspheric surfaces rather than one, but at least one surface must be a symmetric asphere as defined by the following equation: ##EQU3## where X is the aspheric surface point at position Y, r is the central radius and the kappa factor, κ, is a commonly used aspheric constant, wherein the value of κ is less than or equal to 0.5. Preferably, the curvature is hyperbolic, i.e., κ is less than negative one, although a parabolic curvature (κ=-1) or an elliptical curvature (-0.5>κ>-1) is also within the scope of the invention. The aspheric surface may be convex or concave; where there are two aspheric surfaces, each may independently be convex or concave.
The lens of the present invention minimizes the optical aberrations of the lens/eye system. This produces a sharper focus on the retina, as illustrated in FIG. 5. FIG. 5 was generated by computer ray tracing methods, and shows that the blur spot size at the retina is much smaller for a myopic eye corrected with a hyperbolic front curve than for either an emmetropic (i.e., normal) eye or a myopic eye corrected by a spherical lens.
Furthermore, the light tends to be more accurately focused on the retina, as shown in FIG. 6. FIG. 6 was generated by a computer ray trace simultaneously with FIG. 5 and shows the position of the focused image is closest to the retina for the hyperbolic lens/eye system.
As a direct result of these advantages, a lens according to the present invention can provide acceptable vision for those who suffer from astigmatism or presbyopia. The usual approach to correcting astigmatism is to provide a corrective lens that is radially asymmetric in complimentary compensation for the radial asymmetry in either the natural eye lens or in the retina. This approach requires the production and inventory of a large number of lenses to suit not only the basic prescription, but also to provide the complimentary radial asymmetric of the eye. Further, the lens must have a means for maintaining its radial position with respect to the eye in order that the radial variation of the lens matches the eye's radial requirements. Means developed heretofore have not performed with total satisfaction.
Compensation for the non-accommodating natural eye lens is traditionally provided by having a divided lens, with two or more focal lengths to provide far and near vision or, as in some recent designs, a diffractive or refractive lens with two or more focal lengths that can provide adequate near and far vision. This type of system, however, divides the incoming light among the various foci and presents each focus at every point on the retina. Obviously this results in a reduction in the amount of light available for any individual focus and in competing images at each point on the retina.
The aspheric lens does not provide visual compensation to the astigmat or presbyop by graded power or multiple focal lengths, but improves the corrective lens/eye system to the point where, despite the variations caused by asigmatism or presbyopia, the overall performance falls within or near the range of visual acuity of the normal individual.
This occurs because the aforementioned spot size of each point falling on the retina is reduced below that possible by the unaided emmetropic eye alone which contains a natural spherical lens. Because of the optical superiority of the aspheric corrective lens/eye system, the blur of a point on the retina introduced by presbyopia or astigmatism is offset by the aspheric improvement and is thereby less than (or in the range of) that found in the normal eye.
With the proper prescription, virtually any focusing deficiency may be corrected by this lens. Typically, a lens according to the present invention will have an optical power between about +20.00 and about -20.00 diopters.
FIG. 7 illustrates the difference between an aspheric curve 10 as defined in the above equation and a spherical curve 11, where both curves have the same apical radius, r. For a given distance from apex 12, x a or X s , there is a point Y a on the aspheric curve 10 and a point y s on the spherical curve 11. The further X a or X s is from the apex 12, the greater the difference y s -Y a .
A lens having the aforesaid properties is designed by a method wherein ray tracing techniques are used to calculate the path of light rays through a corrective lens/eye system, using a sophisticated mathematical model of a human eye and a corrective lens. The thickness, curvature, and material-dependent refractive index of the lens is varied mathematically and ray tracing calculations are performed on each variation to find the optimal lens for a given eye. The optimal lens is one which results in a sharp focus and a minimum of image aberrations. It has been found that in most cases the optical lens will have a kappa factor in the range of about -0.5 to about -2.
Image analysis involves the tracing of a large number of rays through an optical system. The fundamental equation for tracing a ray, i.e., determining the angle of the ray and its position) from one optical medium to another, via an interface between the media, is by the classic and fundamental Snell's Law equation: n 1 sin θ 1 =n 2 sin θ 2 . For a system of 13 surfaces, this can be very time consuming for even a single ray. Multiple ray analysis using several hundred rays takes a considerable number of operations for even a simple single element lens.
Images can be analyzed in a number of different ways. The classical Seidel aberrations, or reductions in image quality can be calculated by tracing only a few rays. A widely accepted method of quantifying image quality is the MTF, or Modulation Transfer Function. This can be though of as an extension of previous limiting resolution methods.
Referring to FIG. 8, MTF provides modulation, or contrast, resolution (measured from zero to one) versus spatial frequency or fine detail size of an object. The typical Modulation Transfer Function graph shown in FIG. 8 depicts the resolving power of an optical system consisting of a series of lenses, e.g., the human eye with a corrective lens, with that theoretically achievable.
The object bars below the X-axis show, from zero to the cutoff frequency, bars with increasing spatial frequency. The zero to one scale on the Y-axis is the measure of resolution of the bars by an optical system and that theoretically achievable at the diffraction limit. At a Y value of one, the bars are sharply distinguished into black and white images. As the Y value decreases, there is increasing "graying" of white into black of the images. Ultimately at a Y value of zero the bars cannot be distinguished at all.
The modulation can be determined by calculating the graying of the black and white bars at each spatial frequency into a maximum and minimum level. The MTF modulation is the (max-min)/(max-min) contrast. The MTF will be limited in value to a certain level called the "diffraction limit", which would be that level of modulation contrast achievable by a perfect optical system.
The resolving power of an optical instrument of any type is defined as a measure of the sharpness with which small images very close together can be distinguished and is directly proportional to the diameter of the objective aperture and inversely proportional to the wavelength of the light. The interference pattern resulting from rays passing through different parts of an opening or coming from different points around an opaque object and then unite at a point is the manifestation of diffraction. Diffraction and interference effects are characteristic of all wave phenomena. Diffraction thus limits the resolving power of all optical instruments.
When bars of black and white are coarse and widely spaced, a lens has no difficulty in accurately reproducing them. But as the bars get closer together diffraction and aberrations in the lens cause some light to stray from the bright bars into the dark spaces between them, with the result that the light bars get dimmer and the dark spaces get brighter until eventually there is nothing to distinguish light from darkness and resolution is lost.
MTF is calculated by tracing a large number of rays through the system, and evaluating the distribution density of these rays in the image position. The rays at this image position are located in the image "spot". The smaller the spot size, the better the image. The method by which the spot diagram is transformed to the MTF is as follows: the image of a point object is called a point spread function, since some blurring has occured in passing through the system. The image has thus spread. By applying a Fourier Transform function to the point or spot spread function, a graph of the MTF is generated. The MTF frequency goes from zero ("DC" in electrical engineering terms) to the maximum or cutoff frequency, beyond which the object cannot be resolved in the image.
Optical systems can be optimized by varying the thickness, curvature, surface asphericity, material etc. of one or several surfaces. Known numerical methods using computers allow rapid evaluation of the result of varying these parameters, in terms or aberration, spot size or MTF.
This design method requires an analysis of the density of the rays in the image position. This analysis is done by using a Fourier Transform function to generate modulation transfer frequencies. A computer is used to allow the necessarily vast number of calculations to be performed in a reasonable time period. An example of the results of such calculations is presented in FIGS. 9A through 9F. These Figures compare the modulation transfer frequency to the diffraction limit in a myopic eye-lens system, with each figure showing he results for a different lens curvature. These results indicate that the best lenses are those having a surface where κ is between -0.5 and -2.
For the human eye/corrective lens model, one is constrained to changes in the corrective lens.
When used as a contact lens, the present invention preferably comprises a convex aspheric front surface and a concave spherical back surface that conforms to the curvature of the eye for a comfortable fit.
When in the form of an intraocular lens, the lens preferably will have one convex aspheric surface. The opposite surface preferably will be planar, concave spherical, convex aspheric, concave aspherical, or convex spherical. However, other embodiments are possible.
When used in spectacles the lens may comprise front and back surfaces which are independently concave or convex, and either one or both of these surfaces may be aspheric. Typically, the front surface will be convex and the back surface will be concave.
Another approach used to correct visual focal problems is surgical intervention, where the eye is mechanically cut or reshaped by a laser. In particular, excimer laser sculpting methodology is suitable in practicing the present invention. In this case, the appropriate hyperbolic corneal shape for optimal vision would be determined using the method of the present invention, and the shape then produced by this known technique. The result would require no additional corrective lens (even for most astigmats or presbyopes) and produce visual acuity better than a naturally "perfect" spherical lens.
Although the advantages of the present invention may be obtained in a system having a single aspheric surface, the present invention also includes the use of multiple aspheric surfaces, either in a single lens or in a combination of lenses.
A lens according to the present invention may be formed from any suitable high quality optical material, such as optical glass or plastic, but preferably the lens is made of optical quality transparent molded plastic. Suitable materials also include polymers (including fluoropolymers), resinous materials, solid or semi-solid gelatinous materials, rigid gas permeable materials, and the like. A contact lens constructed according to the present invention is preferably made of a hydrophilic polymer polmerized from a methacrylate based monomer. A lens according to the present invention may be incorporated into spectacles, but the preferred embodiments are contact lenses and intraocular lenses.
Many embodiments and variations of this invention will occur to those skilled in the art. The present invention is not limited to the embodiments described and illustrated, but includes every embodiment consistent with the foregoing description and the attached drawings that falls within the scope of the appended claims. | An aspheric lens for providing improved vision and a method for generating such a lens is described. The lens provides a sharp image focus while minimizing image aberrations. The method utilizes ray tracing techniques in conjunction with Modulation Transfer functions to accurately account for the total corrective lens-eye system. The lens may be in the form of a contact lens, an intraocular lens, a natural lens or a spectacle lens, and is suitable for correcting myopia, presbyopia, astigmatism and other focusing problems. The lens is characterized by a hyperbolic or parabolic surface which functions to reduce spherical aberrations and minimize the retinal image spot size. | 6 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.